Models:

005411-0, 005413-0, 005415-0, 005751-0,

005752-0, 005753-0, 005855-0, 005856-0,
005857-0

Owner's Manual

Air-cooled Recreational
Vehicle Generators
RV 45, 55 and 65

www.generac.com or 1-888-GENERAC
 Table of Contents

Part I Operating Instructions Part II Installation Instructions

Introduction .............................................................. 1 Safety Rules ........................................................... 18

Read This Manual Thoroughly........................................... 1 Notice to Installer ............................................................. 18
Contents ............................................................................. 1
Operation and Maintenance .............................................. 1 Section 1 General Information .......................... 20
How to Obtain Service ....................................................... 1 1.1 Purpose and Scope of the Installation
Authorized Service Dealer Locator Number ..........................1 Instructions ................................................................ 20
1.2 Safety ........................................................................ 20
Safety Rules ............................................................. 2 1.3 Standards Booklets .................................................. 20
1.4 Equipment Description ............................................. 20
Section 1 General Information ............................. 4 1.5 Generator Engine Operating Speed ........................ 20
1.1 Generator Identification .............................................. 4 1.6 Generator AC Connection System ........................... 20
1.2 Generator Applicability ............................................... 5
1.3 Installation ................................................................... 5 Section 2 Installation ......................................... 21
1.4 Safety .......................................................................... 5 Major Features and Dimensions .............................. 21
1.5 Generator AC Connection System ............................. 5 2.1 Location and Support ............................................... 22
1.6 Specifications .............................................................. 6 2.2 Generator Compartments ......................................... 23
1.7 Exhaust Emissions Information (Gasoline) ................ 7 2.3 Cooling and Ventilating Air ....................................... 25
1.8 Evaporative Emissions Information ............................ 8 2.4 Gasoline Fuel System ............................................... 27
2.5 Exhaust System ........................................................ 28
Section 2 Operation .............................................. 8 2.6 Electrical Connections .............................................. 29
2.1 Generator Control Panel ............................................. 8
2.7 Battery Installation .................................................... 30
2.2 Optional Remote Start/Stop Panel ............................. 9
2.8 Optional Accessories ................................................ 32
2.3 Automatic Choke ........................................................ 9
2.4 Before Starting the Engine ......................................... 9
Section 3 Post Installation ................................ 33
2.5 Starting the Generator .............................................. 10
3.1 Post Installation Tests ............................................... 33
2.6 Stopping the Generator ............................................ 10
3.2 Before Initial Start-up ................................................ 33
2.7 Applying Loads to Generator ................................... 10
3.3 Initial Start ................................................................. 33
2.8 Protection Systems ................................................... 11
3.4 Testing Under Load................................................... 33
3.5 Installation Checklist ................................................. 34
Section 3 Maintenance........................................ 12
3.1 Checking the Engine Oil Level ................................. 12
Section 4 Troubleshooting .................................. 35
3.2 Changing the Engine Oil and/or Oil Filter ................ 12
4.1 Troubleshooting Guide ............................................. 35
3.3 Maintaining the Engine Air Cleaner .......................... 13
3.4 Checking the Engine Spark Plug ............................. 13
Section 5 Electrical Data..................................... 36
3.5 Fuel Filter (Gasoline Only) ........................................ 13
Section 6 Exploded Views and Parts Lists ........ 40
3.6 Clean Spark Arrestor ................................................ 14
3.7 Cleaning the Generator ............................................ 14
Section 7 Warranty .............................................. 52
3.8 Battery Maintenance ................................................. 14
3.9 Adjusting Valve Clearance ........................................ 15
3.10 Major Service Manual ............................................... 16
3.11 Drive Belt ................................................................... 16
3.12 Exercising the Generator .......................................... 16
3.13 Out of Service Procedure ......................................... 16
3.14 RV Generator Service Interval .................................. 16

INTRODUCTION
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the near-
est Authorized Service Dealer for starting, operating and servicing
procedures.
Throughout this publication, and on tags and decals affixed to the
generator, DANGER, WARNING, CAUTION and NOTE blocks are
used to alert personnel to special instructions about a particular
operation that may be hazardous if performed incorrectly or care-
lessly. Observe them carefully. Their definitions are as follows:
After this heading, read instructions that, if not
strictly complied with, will result in personal
injury, including death, and property damage.
After this heading, read instructions that, if not
strictly complied with, may result in personal
injury or property damage.
After this heading, read instructions that, if not
strictly complied with, could result in damage
to equipment and/or property.
NOTE:
After this heading, read explanatory statements that require
special emphasis.
These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the service are essential to prevent-
ing accidents.
Four commonly used safety symbols accompany the Danger,
Warning and Caution blocks. The type of information each indi-
cates follows:
nThis symbol points out important safety
information that, if not followed, could
endanger personal safety and/or property of
others.
hazard.
This symbol points out potential explosion
This symbol points out potential fire hazard.
shock hazard.
This symbol points out potential electrical
Introduction
The operator (driver) is responsible for proper and safe use of the
vehicle and its equipment, and the safety of all vehicle occupants.
We strongly recommend that the operator read this manual and
thoroughly understand all instructions before using this equipment.
We also strongly recommend instructing other occupants in the
vehicle to properly start and operate the generator. This prepares
them if they need to operate the equipment in an emergency.
CONTENTS
This manual contains pertinent owners information, including
warranty, electrical diagrams, exploded views and lists of repair
parts. In addition, the latter portion of this manual contains infor-
mation necessary for the proper installation of these generators.
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety checks, to
make sure that all maintenance for safe operation is performed
promptly, and to have the equipment checked periodically by
an Authorized Service Dealer. Normal maintenance service and
replacement of parts are the responsibility of the owner/operator
and, as such, are not considered defects in materials or workman-
ship within the terms of the warranty. Individual operating habits
and usage contribute to the need for maintenance service.
Proper maintenance and care of the generator ensures a minimum
number of problems and keep operating expenses at a minimum.
See an Authorized Service Dealer for service aids and acces-
sories.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs, simply contact
an Authorized Service Dealer for assistance. Service technicians
are factory-trained and are capable of handling all service needs.
When contacting an Authorized Service Dealer about parts and
service, always supply the complete model number and serial
number of the unit as given on its data decal, which is located on
the generator.
Model No. _________________ Serial No. ______________
Authorized SERVICE
DEALER LOCATION
To locate the nearest AUTHORIZED SERVICE
DEALER, please call this number:
1-800-333-1322
ONLY DEALER LOCATION INFORMATION
CAN BE OBTAINED AT THIS NUMBER.
1
 Safety Rules
nSAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be
copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to
all operators and potential operators of this equipment.
Study these SAFETY RULES carefully before installing, operating
or servicing this equipment. Become familiar with this manual and
with the unit. The generator can operate safely, efficiently and reli-
ably only if it is properly installed, operated and maintained. Many
accidents are caused by failing to follow simple and fundamental
rules or precautions.
The manufacturer cannot anticipate every possible circumstance
that might involve a hazard. The warnings in this manual, and on
tags and decals affixed to the unit, are, therefore, not all-inclusive.
If using a procedure, work method or operating technique the
manufacturer does not specifically recommend, ensure that it is
safe for others. Also make sure the procedure, work method or
operating technique that chosen does not render the generator
unsafe.
nDespite the safe design of this generator,
operating this equipment imprudently,
neglecting its maintenance or being careless
can cause
possible injury or death. Permit only respon-
sible and capable persons to operate or
maintain this equipment.
these machines. Ensure all steps are taken to
Potentially lethal voltages are generated by
render the machine safe before attempting to
work on the generator.
nParts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects
and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
This product contains or emits chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm.
2
GENERAL HAZARDS
For safety reasons, the manufacturer recommends that the
installation, initial start-up and maintenance of this equipment
is carried out by an Authorized Service Dealer.
The generator engine releases DEADLY carbon monoxide gas
through its exhaust system. This dangerous gas, if breathed
in sufficient concentrations, can cause unconsciousness or
even death. Never operate the generator set with the vehicle
inside any garage or other enclosed area. Shut down the
generator and do not operate it until it has been inspected
and repaired.
DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM
IS LEAKING OR HAS BEEN DAMAGED.
SYMPTOMS OF CARBON MONOXIDE POISONING ARE (a)
inability to think coherently, (b) nausea, (c) vomiting,
(d) twitching muscles, (e) throbbing temples, (f) dizzi-
ness, (g) headaches, (h) weakness, and (i) sleepiness. IF
EXPERIENCING ANY OF THESE SYMPTOMS, MOVE INTO
FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET
MEDICAL HELP.
Never sleep in the vehicle while the genset is running unless
the vehicle has a working carbon monoxide detector. The
exhaust system must be installed in accordance with the
genset installation manual. Make sure there is ample fresh
air when operating the genset in a confined area.
Keep hands, feet, clothing, etc., away from drive belts, fans,
and other moving or hot parts. Never remove any drive belt or
fan guard while the unit is operating.
Adequate, unobstructed flow of cooling and ventilating air is
critical to correct generator operation and is required to expel
toxic fumes and fuel vapors from the generator compartment.
Without sufficient cooling airflow, the engine/generator quickly
overheats, which causes serious damage to the generator. Do
not alter the installation or permit even partial blockage of ven-
tilation provisions, as this can seriously affect safe operation of
the generator.
When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally
fatigued.
Inspect the generator regularly, and contact the nearest
Authorized Service Dealer immediately for parts needing repair
or replacement.
Before performing any maintenance on the generator, discon-
nect its battery cables to prevent accidental start up. Disconnect
the cable from the battery post indicated by a NEGATIVE, NEG
or () first. Reconnect that cable last.
Never use the generator or any of its parts as a step. Stepping
on the unit can stress and break parts, and may result in dan-
gerous operating conditions from leaking exhaust gases, fuel
leakage, oil leakage, etc.

ELECTRICAL HAZARDS
The generator covered by this manual produces dangerous
electrical voltages and can cause fatal electrical shock. Avoid
contact with bare wires, terminals, connections, etc., while the
unit is running. Ensure all appropriate covers, guards and bar-
riers are in place before operating the generator. If work must
be done around an operating unit, stand on an insulated, dry
surface to reduce shock hazard.
Do not handle any kind of electrical device while stand-
ing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
During installation onto the vehicle, have the generator prop-
erly grounded (bonded) either by solid mounting to the vehicle
frame or chassis, or by means of an approved bonding conduc-
tor. DO NOT disconnect the bonding conductor, if so equipped.
DO NOT reconnect the bonding conductor to any generator part
that might be removed or disassembled during routine mainte-
nance. If the grounding conductor must be replaced, use only a
flexible conductor that is of No. 8 American Wire Gauge (AWG)
copper wire minimum.
In case of accident caused by electric shock, immediately
shut down the source of electrical power. If this is not pos-
sible, attempt to free the victim from the live conductor. AVOID
DIRECT CONTACT WITH THE VICTIM. Use a nonconducting
implement, such as a rope or board, to free the victim from the
live conductor. If the victim is unconscious, apply first aid and
get immediate medical help.
Never wear jewelry when working on this equipment. Jewelry
can conduct electricity resulting in electric shock, or may get
caught in moving components causing injury.
Safety Rules
FIRE HAZARDS
For fire safety, the generator must be installed and maintained
properly. Installation always must comply with applicable
codes, standards, laws and regulations. Adhere strictly to local,
state and national electrical and building codes. Comply with
regulations the Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the generator is
installed in accordance with the manufacturers instructions
and recommendations. Following proper installation, do noth-
ing that might alter a safe installation and render the unit in
noncompliance with the aforementioned codes, standards,
laws and regulations.
Keep a fire extinguisher in the vehicle at all times. Extinguishers
rated ABC by the National Fire Protection Association are
appropriate for use on the recreational vehicle generator elec-
trical system. Keep the extinguisher properly charged and be
familiar with its use. If there are any questions pertaining to fire
extinguishers, consult the local fire department.
EXPLOSION HAZARDS
Do not smoke around the generator. Wipe up any fuel or oil
spills immediately. Ensure that no combustible materials are left
in the generator compartment, or on or near the generator, as
FIRE or EXPLOSION may result. Keep the area surrounding the
generator clean and free from debris.
Gasoline is extremely FLAMMABLE and its vapors are
EXPLOSIVE. Do not permit smoking, open flame, sparks or any
source of heat in the vicinity while handling gasoline. Comply
with all laws governing the storage and handling of gasoline.
This generator may use liquid propane (LP) gas as a fuel. LP
gas is highly EXPLOSIVE. The gas is heavier than air and tends
to settle in low areas where even the slightest spark can ignite
the gas and cause an explosion.
3
General Information

1.1 GENERATOR IDENTIFICATION

Please record the following information from the generator DATA DECAL or information decal.
1. Model Number ____________________ 2. Serial Number _________________
3. kW Rating _________________________ 4. Rated Voltage _________________
5. Phase _____________________________ 6. Hertz __________________________

18 8 2 15

13

10, 17 3 4 5 1 12 11 14 16

7 10
9, 17

REFERENCE NUMBER IDENTIFICATION

1. Generator Air Intake 10. Fuel Pump
2. Data Plate 11. Oil Filter
3. Engine Start/Stop Switch 12. Oil Drain Plug
4. 7.5 amp Fuse 13. Oil Dipstick and Filler Tube
5. Circuit Breaker 14. Air Filter (Behind access panel.)
6. Optional Remote Panel Receptacle 15. Spark Plugs
7. Generator AC Output Leads 16. Exhaust Outlet
8. Starter Contactor 17. Fuel Filter
9. Fuel Inlet 18. Evaporative Port

4
 General Information

1.2 GENERATOR APPLICABILITY 1.3 INSTALLATION

These generators have been designed and manufactured for sup- This Owners Manual has been prepared under the assumption
plying electrical power for recreational vehicles. DO NOT modify that a competent, qualified technician installed the generator into
the generator or use it for any application other than for what it a recreational vehicle. We also assume the installer complied
was designed. If there are any questions pertaining to its applica- with all applicable codes, standards and regulations pertaining to
tion, write or call the factory. Do not use the unit until advised by installation.
competent authority. An INSTALLATION MANUAL was shipped with the generator. That
Manual contains manufacturers instructions and recommenda-
tions for installing the unit into an industrial vehicle. After installa-
properly installed in compliance with ANSI
For fire safety, the generator must have been tion, installers should forward the Installation Manual to Owners/
Operators for their information.
119.2-1975/NFPA 501C-1974, Standard for
Recreational Vehicles, Part III Installation Owners/Operators have the responsibility to make sure that noth-
of Electrical Systems. The generator also ing is done that might render the installation unsafe or in non-
must have been installed in strict compliance compliance with applicable codes, standards and instructions.
with the manufacturers detailed installation
instructions. After installation, do nothing
that might render the unit in noncompliance
1.4 SAFETY
Before using the generator set, carefully read GENERAL SAFETY
with such codes, standards and instructions. RULES inside the cover. Comply with these RULES to prevent
Use the generator set to supply electrical power for operating one accidents and damage to equipment and/or property. The manu-
of the following electrical loads: facturer suggests copying and posting the GENERAL SAFETY
RV 45 G: 120 and/or 240 volts, single phase, 60 Hz electrical RULES to potential operators of this equipment.
loads. These loads can require up to 4500 watts (4.5 kW) of
total power, but cannot exceed 37.5 AC amperes of current at 1.5 GENERATOR AC CONNECTION
120 volts (breaker is limited to 30 Amps).
RV 55 G: 120 and/or 240 volts, single phase, 60 Hz electrical SYSTEM
loads. These loads can require up to 5500 watts (5.5 kW) of These air-cooled generator sets are equipped with dual stator
total power, but cannot exceed 45.8 AC amperes of current at AC power windings. These two stator windings supply electrical
120 volts or exceed 22.9 AC amperes at 240 volts. power to customer electrical loads by means of a dual 2-wire
connection system.
RV 65 G: 120 and/or 240 volts, single phase, 60 Hz electrical
loads. These loads can require up to 6500 watts (6.5 kW) of Generators may be installed to provide the following outputs:
total power, but cannot exceed 54.1 AC amperes of current at 1. 120 VAC loads only two loads, each with a maximum
120 volts or exceed 27 AC amperes at 240 volts. total wattage requirement equal to half of the generators
rated power output (in watts), and 120V across the generator
output terminals. Figure 1.1 shows the generator lead wire
Do not overload the generator. Some instal- connections for 120VAC ONLY.
n
lations may require that electrical loads be
alternated to avoid overloading. Applying Figure 1.1 Connection for 120 Volts Only
excessively high electrical loads may dam-
age the generator and may shorten its
life. Add up the rated watts of all electrical
lighting, appliance, tool and motor loads
the generator will power at one time. This
total should not be greater than the watt-
age capacity of the generator. If an electri-
cal device nameplate gives only volts and
amps, multiply volts times amps to obtain
watts (volts x amps = watts). Some elec-
tric motors require more watts of power (or
amps of current) for starting than for con-
tinuous operation.

5
 General Information

2. 120/240 VAC loads one load with a maximum total watt-
age requirement equal to the generators rated power output,
and 240V across the generator output terminals; or two sepa-
rate loads, each with a maximum total wattage requirement
equal to half of the generators rated power output (in watts),
and 120V across the generator output terminals. Figure 1.2,
shows the generator lead wire connections for 120/240 VAC
loads. Also refer to the "Line Breakers" section for circuit
breaker ratings.
This procedure should be done by an Authorized Service Dealer or
other qualified installer.
Figure 1.2 - Connection for 120/240 Volts
NOTE
Some installations using a shared fuel tank may have a gen-
erator fuel pickup tube that is shorter than the vehicle engines
pickup tube. Such an arrangement causes the generator engine
to run out of gas while adequate fuel for the vehicle remains
in the tank.
To reduce lead and carbon deposits use high quality UNLEADED
gasoline with the generator. Leaded REGULAR grade gasoline is an
acceptable substitute.
NOTE:
Using unleaded gasoline contributes to longer engine valve life by
reducing lead and carbon deposits.

T1
RED
CB1
nThe manufacturer does not recommend
using any gasoline containing alcohol (such
as gasohol). If using any gasoline contain-
ing alcohol, it must not contain more than
10 percent ethanol (Do not use E85), and it
must be removed from the generator during
storage. Do NOT use any gasoline contain-
T2 ing methanol. If using gasoline with alcohol,
WHITE
inspect more frequently for fuel leaks and
other abnormalities.

1.6.2 ENGINE OIL REQUIREMENTS

All oil should meet minimum American Petroleum Institute (API)
CB2 Service Class SJ, SL or better. Use no special additives. Select the
T3
BLACK oil's viscosity grade according to the expected operating tempera-
STATOR POWER GROUNDED NEUTRAL ture (also see chart).
WINDINGS SAE 30 Above 32 F
10W-30 Between 40 F and -10 F
Synthetic 5W-30 10 F and below
1.6 SPECIFICATIONS
1.6.1 FUEL REQUIREMENTS (GASOLINE) SAE 30

This generator is equipped with a gasoline fuel system as standard

equipment. Specific installations may provide either a separate fuel 10 W-30
10W-30
tank for the generator, or the generator may share the vehicle
engines fuel tank. Sy nthe
nthetic
tic 5
5W-30
W-3 0

1.6.1.1 Fuel Consumption (gph)

Model 10% Load 50% Load 100% Load
RV45G .33 .45 .73
RV55G .35 .55 .89
Crankcase and oil filter capacity is approximately 1.4 L or 1.5 U.S.
RV65G .37 .65 .97 quarts. DO NOT use special additives. See sections "Checking the
Engine Oil Level" and "Changing the Engine Oil and/or Oil Filter" for
oil level check and filling procedures.

6
 General Information

1.6.3 GENERATOR SPECIFICATIONS

SERIES RV45G RV55G RV65G
Rotor RPM 3600 3600 3600
Rotor Poles 2 2 2
Engine RPM 2571 2571 2571
Rated Max. Continuous AC Output Watts* 4500 5500 6500
Voltage* 120 120 120
Rated Max. Continuous Current Amps (240V) 37.5 (18.7) 45.8 (22.9) 54.1 (27)
Phase 1 1 1
Frequency 60 Hertz 60 Hertz 60 Hertz
Weight 278 lbs. 285 lbs. 293 lbs.
Length 33.7 in. 33.7 in. 33.7 in.
Width 21.5 in. 21.5 in. 21.5 in.
Height 16.8 in. 16.8 in. 16.8 in.
* All units are re-connectable to 120 and/or 240 volts, dual voltage output. Units are not listed per RVIA/ANSI when reconnected for dual voltage output
** Maximum wattage and current are subject to, and limited by, such factors as fuel Btu content, ambient temperature, altitude, engine condition, etc.. Maximum power
decreases about 3.5% for each 1,000 feet above sea level; and will also decrease about 1% for each 6 C (10 F) above 16 C (60 F) ambient temperature.

1.6.4 ENGINE SPECIFICATIONS Fuel Metering System

Type of Engine ........................................................................GT-530 ~ Carburetor assembly
Cooling Method ................................................................ Air-cooled ~ Fuel pump and lines
Rated Horsepower ...................................................18 at 3600 rpm Air Induction System
Displacement ........................................................................... 530cc ~ Intake pipe / manifold
Compression Ratio ................................................................8.5 to 1 ~ Air cleaner
Cylinder Block.................................. Aluminum w/Cast Iron Sleeve Ignition System
Type of Governor .......................................Electronic, Fixed Speed ~ Spark plug
Engine Governor Speed ................................................... 2571 rpm
~ Ignition module
Air Cleaner................................................................. Paper Element
Starter .................................................................. 12-volt DC Electric
Catalytic Converter (if equipped)
Ignition System ............................ Solid-state w/Flywheel Magneto The Emissions Compliance Period referred to on the Emissions
Recommended Spark Plug Compliance Label indicates the number of operating hours for
NGK ....................................................................................BPR6HS which the engine has been shown to meet Federal and California
Spark Plug Gap ............................................. 0.030 inch (0.76 mm) emission requirements. See the table below to determine the com-
Recommended Min. Battery.................. 400 Cold Cranking Amps pliance period for this generator. The displacement of the engine is
Class II Emission Certified listed on the Emissions Compliance Label.

1.7 EXHAUST EMISSIONS Displacement Category Compliance Period

A 500 Hours
INFORMATION (GASOLINE) > 66 cc - < 225 cc B 250 Hours
The Environmental Protection Agency (EPA) and the California Air
Resource Board (CARB) require that this generator comply with C 125 HOurs
exhaust emission standards. The generator is certified to meet all
A 1000 Hours
applicable exhaust emission levels. This generator is certified for
use as a mobile engine. It is important that you follow the mainte- 225 cc B 500 Hours
nance specifications listed in this manual to ensure that the engine C 250 Hours
complies with emission standards for the duration of its life. This
engine is certified to operate on gasoline. The emission control
system on the generator consists of the following:

7
 Operation

1.8 EVAPORATIVE EMISSIONS Figure 2.1 Typical Control Panel

INFORMATION
This generator is subject to evaporative emission standards which
have been implemented by the California Air Resource Board
(CARB) and the Environmental Protection Agency (EPA). If this
generator is offered for sale in the state of California, it must be
covered by a CARB evaporative Executive Order. If this generator
is offered for sale to the final consumer in any other state, certified
low-permeation fuel line must be used to supply fuel to the genera-
tor as required by EPA.
Anyone who installs or configures a fuel system to supply this
generator with gasoline is required to comply with all applicable
evaporative emission regulations. If this generator is configured
such that it shares the primary fuel system of a vehicle in which it
is installed, reduced certification requirements may apply. See the
CARB guidance document MAC 05-05, located at http://www.arb.
ca.gov/msprog/macs/mac0505/mac0505.pdf for further details. If The switch center position is the RUN position.
this generator is installed such that it uses a dedicated fuel system, To stop a running engine, press momentarily the bottom half of the
detailed evaporative emission requirements apply; contact a repu- switch to kill the ignition.
table fuel system manufacturer to purchase a complete fuel sys-
tem certified for use with this generator, or consult the California
Code of Regulations if you wish to obtain certification on your 2.1.2 7.5 AMP FUSE
own. See the installation instructions in this manual for connecting The fuse protects the engines DC control circuit against electrical
fuel system vapor lines to the engine. overload. If the fuse element has melted open due to overloading,
This generator is not legal for sale in the state of California unless the engine cannot be cranked. If the fuse must be replaced, use
all CARB evaporative emission requirements are adhered to, and only an identical 7.5 amp replacement fuse.
is not legal for sale in any other state unless certified low-per-
meation fuel line is used to supply the generator with gasoline.
Contact the California Air Resource Board or the Environmental 2.1.3 LINE BREAKERS
protection agency for further information. CARB regulations can Protects generators AC output circuit against overload, i.e., pre-
be found in 13 CCR 2750 2773; EPA regulations can be
vents unit from exceeding wattage/amperage capacity. The circuit
found in 40 CFR Part 90.
breaker ratings are as follows:

2.1 GENERATOR CONTROL PANEL Model Cir. Breaker 1 Cir. Breaker 2 240 Volt
The following features are mounted on the generator control panel RV45 30A N/A N/A
(Figure 2.1):
RV55 20A 30A 25A 2P

2.1.1 START/STOP SWITCH RV65 30A 30A 30A 2P

This generator is started with a "One Touch" starting sequence. NOTE:

Push up on the top half of the momentary switch. Hold for one
(1) second and release. Note flashing indicator light on the switch. If this generator has been reconnected for dual voltage AC out-
Fuel pump engages automatically for a three (3) to five (5) second put (120/240 volts), install line breakers having an amperage
delay before starter motor cranks the engine for 16 seconds or rating equal to that stated in the preceding chart. The replace-
until the engine starts. If the engine does not start, the starter ment line breakers consist of two separate breakers with a
will cool for seven (7) seconds and crank the engine again for 16 connecting piece between the breaker handles (so that both
seconds. If the engine does not start, the starter will cool for seven breakers will operate at the same time). If the unit is recon-
(7) seconds before cranking for seven (7) seconds to a maximum nected for dual voltage, it is no longer RVIA listed.
cycle total of 90 seconds. Once started, the light on the switch
stays on continuously. If the generator does not start at the end
of the start sequence, a fault code will flash on the switch (see
Diagnostics).
The switch center position is the RUN position.
To stop a running engine, press momentarily the bottom half of the
switch to kill the ignition.

8

2.1.4 DIAGNOSTICS
If the generator shuts down due to a fault, the indicator will flash a
code to identify the problem.
2 Flashes = Low Battery (Voltage falls below 11.0 VDC for one
minute)
NOTE:
Alarm will clear automatically if voltage rises over 11.0 VDC.
Battery voltage is not monitored during crank cycle.
3 Flashes = Overcrank (Unit does not start through entire start
cycle)
4 Flashes = Overspeed (Alternator spins at 4200 rpm/72 Hz
or greater)
5 Flashes = Low Oil Pressure (Drops below the 5 psi threshold
of the switch)
NOTE:
There is a five second delay of the alarm when the engine is
first started up.
6 Flashes = High Oil Temperature (Unit shuts down when tem-
perature switch limit is reached)
NOTE:
As the unit cools down it will attempt to restart automatically
when the temperature switch opens again.
7 Flashes = Underspeed (Alternator spins less than 3240
rpm/54 Hz for three (3) seconds)
NOTE:
After a fault is indicated, press stop momentarily to clear the
alarm once the problem is fixed.
2.2 OPTIONAL REMOTE
START/STOP PANEL
A remote mounted Start/Stop Panel is available that allows start-
ing and stopping the generator engine conveniently from inside the
vehicle. The remote panel includes a Start/Stop switch, hourmeter,
generator run lamp, and a wire harness.
2.3 AUTOMATIC CHOKE
This engine is equipped with an automatic choke that consists of
two main components: a choke solenoid and prechoke (Gasoline
only.).
2.3.1 CHOKE SOLENOID
During engine cranking (Start/Stop switch at START), a solid-state
choke module signals the choke solenoid to activate and cycle
(choke on/choke off) until the engine starts. The choke solenoid
thus opens and closes the carburetor choke valve only when
the engine is cranking. When the engine starts, the choke stops
cycling (Gasoline only.).
Operation
2.3.2 PRECHOKE
The choke system also has a temperature-sensitive metal strip that
adjusts choke valve angle according to ambient temperatures (i.e.,
in cold ambient temperatures, choke valve closes more). Once the
engine starts, an element heats the temperature-sensitive strip to
a normal operating condition, opening the choke valve. This may
take about three minutes in cooler weather (Gasoline only.).
2.4 BEFORE STARTING THE
ENGINE
NOTE:
Instructions and information in this manual assume the genera-
tor has been properly installed, connected, serviced, tested and
adjusted by a qualified installation technician or installation
contractor.
2.4.1 INSTALLATION
Generator installation must have been properly completed so it
complies with all applicable codes, standards and regulations
and with the manufacturer's recommendations. (See Part II -
Installation Instructions.)
2.4.2 ENGINE LUBRICATION
Have the engine crankcase properly serviced with the recommend-
ed oil before starting. Refer to sections "Engine Specifications",
"Checking the Engine Oil Level" and "Changing the Engine Oil and/
or Oil Filter" for oil servicing procedures and recommendations.
nAny attempt to crank or start the engine
before it has been properly serviced it with
the recommended oil may result in an engine
failure.
2.4.3 FUEL SUPPLY
The engine must have an adequate supply of proper fuel to oper-
ate. Before starting it, check that sufficient fuel is available.
NOTE:
Depending on the installation, the generator may have either a
separate fuel tank, or it may share the vehicle engines fuel
tank.
2.4.4 COOLING AND VENTILATING AIR
Air inlet and outlet openings in the generator compartment must
be open and unobstructed for continued proper operation. Without
sufficient cooling and ventilating airflow, the engine/generator
quickly overheats, which causes it to shut down and may damage
the generator.
9
 Operation
2.4.5 ENGINE EXHAUST GAS
Before starting the generator engine, be sure there is no way for
exhaust gases to enter the vehicle interior and endanger people or
animals. Close windows, doors and other openings in the vehicle
that, if open, might permit exhaust gases to enter the vehicle.
nThe generator engine releases DEADLY
carbon monoxide gas through its exhaust
system. This dangerous gas, if breathed in
sufficient concentrations, can cause uncon-
sciousness or even death. Never operate
the generator set with the vehicle inside
any garage or other enclosed area. DO NOT
OPERATE THE GENERATOR IF THE EXHAUST
SYSTEM IS LEAKING OR HAS BEEN
DAMAGED. Shut down the generator and
do not operate it until it has been inspected
and repaired. SYMPTOMS OF CARBON
MONOXIDE POISONING ARE (a) inability to
think coherently, (b) nausea, (c) vomiting, (d)
twitching muscles, (e) throbbing temples, (f)
dizziness, (g) headaches, (h) weakness, and
(i) sleepiness. IF EXPERIENCING ANY OF
THESE SYMPTOMS, MOVE INTO FRESH AIR
IMMEDIATELY. IF SYMPTOMS PERSIST, GET
MEDICAL HELP.
nNever sleep in the vehicle while the genset
is running unless the vehicle has a working
carbon monoxide detector. The exhaust sys-
tem must be installed in accordance with the
genset installation manual. Make sure there
is ample fresh air when operating the genset
in a confined area.
2.5 STARTING THE GENERATOR
NOTE:
Read the vehicle manufacturers instructions. The owner/
operator should become familiar with the vehicle in which this
generator is installed. Differences exist between vehicles. For
example, some vehicles may use a transfer switch to isolate
dockside power from the generator, while other vehicles may
use an isolating receptacle. Some vehicles may be equipped
with a DC converter which allows the generator to power certain
DC lighting and other DC loads.
To crank and start the generator engine, proceed as follows:
1. Turn OFF electrical loads using the means provided in the
vehicle (such as a main line circuit breaker or transfer
switch).
10
NOTE:
If starting from the generator control panel, turn OFF loads
by setting the generators main circuit breaker to the OFF (or
open) position. If starting from a remote panel, turn OFF loads
using the means provided in the vehicle (such as a main circuit
breaker). Electrical load circuits should be turned ON after the
generator has started, stabilized and warmed up.
2. To crank and start the engine, push up on the Start/Stop
switch momentarily and release. There is a delay as the fuel
pump primes and the generator automatically begins the start
sequence (Note the flashing light on the switch.).
3. Let the engine run at no-load for a few minutes to stabilize and
warm up.
4. Turn ON electrical loads using the means provided (such as a
main circuit breaker or transfer switch).
2.6 STOPPING THE GENERATOR
1. Turn OFF all electrical loads using the means provided (such
as a main circuit breaker or transfer switch).
2. Let generator run at no-load for a few minutes, to stabilize
internal engine generator temperatures.
3. Place the Start/Stop switch in its STOP position. The engine
will come to a complete stop.
2.7 APPLYING LOADS TO
GENERATOR
When applying electrical loads to the generator, observe these
guidelines:
Before applying electrical loads, let the generator stabilize and
warm up for a minute or two.
DO NOT overload the generator.
2.7.1 LETTING THE ENGINE STABILIZE
The generator supplies correct rated voltage only at the proper
governed speed. Some electrical appliances may be extremely
sensitive to voltage. Incorrect voltages can damage such appli-
ances.
If electrical loads are applied at reduced operating speeds, such
loads imposed on the engine when sufficient power is not available
may shorten engine life. Never turn ON electrical loads until after
the generator engine has started and stabilized at no-load.
2.7.2 DO NOT OVERLOAD THE GENERATOR
Read the rated wattage/amperage capacity of the generator on the
generator data label (See the "Generator Identification" section.).
Applying electrical loads in excess of the units rated capacity will
cause the engine/generator to automatically shut down.
To avoid overloading, add up the wattage of all connected electrical
lighting, appliance, tool and motor loads. This total should not be
greater than the generators rated wattage capacity.
 Operation

Most lighting, appliance, tool and motor loads indicate their
required watts on their nameplate or data plate. For light bulbs,
simply note the wattage rating of the bulb.
If a load does not show its rated wattage, multiply that loads
rated VOLTS times AMPS to obtain WATTS.
Induction type motors (such as those that run the vehicles
furnace fan, refrigerator, air conditioner, etc.) need about 2-1/2
times more watts of power for starting than for running (for a
few seconds during motor starting). Be sure to allow for this
when connecting electrical loads to the generator. First, figure
the watts needed to start electric motors in the system. To that
figure, add the running wattages of other items that will be oper-
ated by the generator.
Do not apply heavy electrical loads for the first two or three
hours of operation.
2.8.3 FIELD BOOST
The Controller Circuit Board houses a field boost diode and resistor
that are not part of the automatic choke circuit. These two compo-
nents are part of a field boost circuit (Figure 2.3). During engine
cranking only, a positive DC (battery) voltage is delivered through
a diode, resistor, brushes, slip rings, and the generator rotor.
Application of this voltage to the rotor flashes the field whenever
it is started. Flashing of the field each time the generator starts
makes sure that a sufficiently strong magnetic field is available to
produce pickup voltage in the stator windings.
Figure 2.3 Field Boost Circuit

2.8 PROTECTION SYSTEMS

2.8.1 LOW OIL PRESSURE SWITCH
This switch (Figure 2.2) has normally closed (N.C.) contacts that
are held open by engine oil pressure during cranking and operat-
ing. Should oil pressure drop below a preset level, switch contacts
close, and the engine automatically shuts down. The unit should
not be restarted until oil is added.

2.8.2 HIGH TEMPERATURE SWITCH

This switch (Figure 2.2), which has normally open (N.O.) contacts,
is mounted near the oil filter. The contacts close if the temperature
should exceed approximately 270 F (132 C) for gasoline mod-
els.
Figure 2.2 Low Oil Pressure and
High Temperature Switches
2.8.4 OVERVOLTAGE PROTECTION
A solid-state voltage regulator (Figure 2.4) controls the generators
AC output voltage. This regulator supplies an excitation current to
the rotor. By regulating the rotors excitation current, the strength
of its magnetic field is regulated and, in turn, the voltage delivered
to connected electrical loads is controlled. When the AC frequency
is 60 Hertz, voltage is regulated at 125 to 120 volts.

Figure 2.4 Solid State Voltage Regulator

11
 Maintenance
2.8.5 OPERATION IN HIGH GRASS OR BRUSH
is parked over high grass, weeds, brush,
Never operate the generator while the vehicle
leaves or any other combustible substance.
Such materials can ignite and burn from the
heat of the exhaust system. The generator
exhaust system becomes extremely hot dur-
ing operation and remains hot for a long time
after it has shut down.
3.1 CHECKING THE ENGINE OIL
LEVEL
For oil capacities and requirements, see the Engine Oil
Requirements section. Check the engine crankcase oil level at
least every eight hours of operation, or before it is used. To check
the engine oil level, proceed as follows (see Figure 3.1):
1. Be sure the generator is as level as possible.
2. Remove the dipstick and wipe it dry with a clean, lint-free
cloth.
3. Install and tighten the dipstick cap; then, remove it again. The
oil level should be at the dipstick Full mark.
4. If necessary, remove the oil fill cap on the rocker cover and
slowly add oil until it reaches the dipstick Full mark. DO NOT
FILL ABOVE THE FULL MARK.
nNever operate the engine with the oil level
below the Add mark on the dipstick. Doing
this could damage the engine.
5. Install and tighten the oil fill cap and the dipstick before oper-
ating the engine.
Figure 3.1 Oil Dipstick/Fill Tube and
Location of Oil Drain Plug
Oil Fill Oil Drain Hose Oil Dipstick
12
3.2 CHANGING THE ENGINE OIL
AND/OR OIL FILTER
nHot oil may cause burns. Allow engine to
cool before draining oil. Avoid prolonged
or repeated skin exposure with used oil.
Thoroughly wash exposed areas with soap.
Oil Change Intervals see Section RV Generator Service
Interval.
To change the oil and oil filter, proceed as follows:
1. Run the engine until it is thoroughly warmed up (at least five
minutes) then shut off the engine.
2. With the engine still warm from running, remove the round
access grommet from underneath the front of the generator.
Place a suitable container underneath to catch all the drain
oil.
3. Use the 0G4818 tool (supplied with the generator) to turn the
old filter counter-clockwise and remove. Let oil drain into the
container located directly below.
4. Locate the oil drain hose inside and pull the yellow drain plug
out of the access hole (Figure 3.1).
5. Turn the yellow cap counter-clockwise to remove and finish
draining the old oil.
6. After the oil has been drained, replace the oil drain plug by
tightening it clockwise and return.
7. Clean off the oil filter bracket and any old oil that may have
spilled while draining.
8. Apply a light coating of clean engine oil the gasket of the new
oil filter (Figure 3.2).
9. Screw the new oil filter on by hand until its gasket lightly con-
tacts the oil filter adapter. Then, tighten the filter an additional
to one turn. Replace and secure the round access grom-
met.
Figure 3.2 Engine Oil Filter
Engine
Oil Filter
Twist Counter-clockwise to Loosen
 Maintenance

10. Remove the dipstick, valve cover plug and add new oil (see
Engine Oil Requirements) to engine. DO NOT FILL ABOVE
3.4 CHECKING THE ENGINE
THE FULL MARK. SPARK PLUG
11. Install and tighten plug and dipstick before starting the Reset the spark plug gap or replace the spark plugs as necessary.
engine. See the Service Schedule section for maintenance requirements.
12. Start engine and check for leaks. 1. Clean the area around the base of the spark plugs to keep dirt
NOTE: and debris out of the engine.
Check the oil level and fill to the FULL mark after checking for 2. Remove the spark plugs and check the condition. Replace the
leaks. The filter will retain some oil. spark plugs if worn or if reuse is questionable. See the Service
Schedule section for recommended interval. Clean by scrap-
ing or washing using a wire brush and commercial solvent.
3.3 MAINTAINING THE ENGINE Do not blast the spark plugs to clean.
AIR CLEANER 3. Check the spark plug gap using a wire feeler gauge. Adjust the
gap to 0.76mm (0.030 inch) by carefully bending the ground
Replace the paper air filter element after every 200 hours of opera-
electrode if necessary (Figure 3.4).
tion. (Perform more often when operating in dusty conditions)
1. At the Air Cleaner Cover, turn the yellow plastic knob turn Figure 3.4 Setting the Spark Plug Gap
counter-clockwise.
2. Pull the top of the Cover out as it hinges on the bottom of the
Air Cleaner Base.
3. Separate the Cover by lifting up and out from the Base.
4. Pull the old filter out and discard safely.
5. Install the new filter in place on the Air Cleaner Base (Figure
3.3).
6. Interlock the Air Cleaner Cover to hinge with the Air Cleaner
Base.
7. Align the Cover and gently push the top closed.
8. Engage the yellow plastic knob and turn turn clockwise to
secure.

Figure 3.3 Engine Air Cleaner

nSparking can occur if the wire terminal does
not fit firmly on the spark plug terminal end.
If necessary, re-form the wire terminal to
Air Cleaner Base obtain a tight fit.

3.5 FUEL FILTER (GASOLINE ONLY)

Air Cleaner Remove and replace the fuel filter (Figure 3.5) every 400 hours of
operation.

Figure 3.5 Fuel Filter

Knob
FUEL FILTER
TO FUEL PUMP

Air Cleaner Cover

CUSTOMER FUEL CONNECTION

13
 Maintenance
3.6 CLEAN SPARK ARRESTOR
The engine exhaust muffler has a spark arrestor screen. Inspect and
clean the screen every 200 hours of operation or once each year,
whichever comes first.
NOTE:
If using the generator on any forest-covered, brush-covered or
grass-covered unimproved land, it must equipped with a spark
arrestor. The spark arrestor must be maintained in good condi-
tion by the owner/operator.
Clean and inspect the spark arrestor as follows:
Remove the screen by removing the screw.
Slide the spark arrestor screen out from the tail pipe.
Inspect screen and replace if torn, perforated or otherwise
damaged. DO NOT USE a defective screen. If screen is not
damaged, clean it with commercial solvent.
Replace the screen and the screw.
Figure 3.6 - Spark Arrestor
TAILPIPE
P/N 0G5857
SPARK ARRRESTOR
SCREEN P/N 089680
RETAINING
SCREW P/N 056892
3.7 CLEANING THE GENERATOR
Keep the generator set as clean and dry as possible. Protect the
unit against excessive dust, dirt, corrosive vapors, road splash,
etc. Permitting dirt and moisture to accumulate on generator
windings will have an adverse effect on the insulation resistance
of those windings.
When moisture is allowed to remain in contact with windings,
some of the moisture will be retained in voids and cracks in the
insulation. This causes a reduced insulation resistance and will
eventually cause problems. Dirt will make the problem worse,
since dirt tends to hold moisture in contact with windings. Salt (as
from sea air) also will worsen the problem since it tends to absorb
moisture from the air. Salt and moisture, when combined, form a
good electrical conductor which is detrimental to the generator.
14
nDo NOT use a forceful spray of water to
clean the generator. Water will enter the gen-
erator interior and cause problems, and may
also contaminate the generator fuel system.
3.8 BATTERY MAINTENANCE
NOTE:
This generator is not equipped with an internal battery charger.
It is intended for use in systems where an external battery char-
ger is installed by the RV O.E.M. or an aftermarket installer.
All lead-acid batteries will discharge when not in use. The generator
battery should be inspected as follows:
3.8.1 WEEKLY
Inspect the battery posts and cables for tightness and corro-
sion. Tighten and clean as necessary.
Check the battery fluid level of unsealed batteries and, if nec-
essary, fill with Distilled Water Only. Do not use tap water in
batteries.
3.8.2 EVERY SIX MONTHS
Have the state of charge and condition checked. This should be
done with an automotive-type battery hydrometer.
NOTE:
Servicing of the battery is to be performed or supervised by
personnel knowledgeable of batteries and the required precau-
tions. Keep unauthorized personnel away from batteries.
Damage will result if the battery connections are made in
reverse.
battery is capable of exploding. Storage bat-
Do not dispose of the battery in a fire. The
teries give off explosive hydrogen gas. This
gas can form an explosive mixture around
the battery for several hours after charging.
The slightest spark can ignite the gas and
cause an explosion. Such an explosion can
shatter the battery and cause blindness or
other injury. Any area that houses a storage
battery must be properly ventilated. Do not
allow smoking, open flame, sparks, or any
spark producing tools or equipment near the
battery. Discharge static electricity from body
before touching the battery by first touching
a grounded metal surface.

and high short circuit current. The following
A battery presents a risk of electrical shock
precautions are to be observed when work-
ing on batteries:
Remove watches, rings or other metal objects;
Use tools with insulated handles;
Wear rubber gloves and boots;
Do not lay tools or metal parts on top of the
battery;
Disconnect any charging source prior to connect-
ing or disconnecting battery terminals; and
Do not use any jumper cables or booster battery
to crank and start the generator engine. If any
battery has discharged, remove it for recharging.
Do not open or mutilate the battery.
n
Released electrolyte has been known to
be harmful to the skin and eyes, and to be
toxic.
The electrolyte is a dilute sulfuric acid that
n is harmful to the skin and eyes. It is electri-
cally conductive and corrosive. The follow-
ing procedures are to be observed:
Wear full eye protection and protective clothing;
Where electrolyte contacts the skin, wash it off
immediately with water;
Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and
seek medical attention; and
Spilled electrolyte is to be washed down with
an acid neutralizing agent. A common practice
is to use a solution of 1 pound (500 grams)
bicarbonate of soda to 1 gallon (4 liters) or
water. The bicarbonate of soda solution is to
be added until the evidence of reaction (foam-
ing) has ceased. The resulting liquid is to be
flushed with water and the area dried.
3.9 ADJUSTING VALVE CLEARANCE
After the first 50 hours of operation, check the valve clearance
in the engine, adjust if necessary.
Important: If feeling uncomfortable about doing this procedure or
the proper tools are not available, please contact the Authorized
Dealer for service assistance. This is a very important step to
insure longest life for the engine.
To check valve clearance:
The engine should be cool before checking. If valve clearance is
0.002" - 0.004" (0.05 - 0.1mm), adjustment is not needed.
Remove spark plug wires and position wires away from plugs.
Remove spark plugs.
Maintenance
Make sure the piston is at Top Dead Center (TDC) of its com-
pression stroke (both valves closed). To get the piston at TDC,
remove the intake screen at the front of the engine to gain
access to the flywheel nut. Use a large socket and socket
wrench to rotate the nut and hence the engine in a clockwise
direction. While watching the piston through the spark plug
hole. The piston should move up and down. The piston is at
TDC when it is at its highest point of travel.
To adjust valve clearance (if necessary):
Make sure the engine is at 60 to 80 F.
Make sure that the spark plug wire is removed from the spark
plug and out of the way.
Remove the four screws attaching the valve cover with a #2 or
#3 Phillips screwdriver.
Loosen the rocker jam nut. Use an 10mm allen wrench to turn
the pivot ball stud while checking clearance between the rocker
arm and the valve stem with a feeler gauge. Correct clearance
is 0.002-0.004 inch (0.05-0.1 mm). (Figure 3.7).
Figure 3.7 - Valve Clearance Adjustment
Rocker
Pivot Ball Arm
Stud
Jam Nut
Valve
Stem
NOTE:
Hold the rocker arm jam nut in place as the pivot ball stud is
turned.
When valve clearance is correct, hold the pivot ball stud in place
with the allen wrench and tighten the rocker arm jam nut. Tighten
the jam nut to 174 in/lbs. torque. After tightening the jam nut,
recheck valve clearance to make sure it did not change.
Install new valve cover gasket.
Re-attach the valve cover.
NOTE:
Start all four screws before tightening or it will not be possible
to get all the screws in place. Make sure the valve cover gasket
is in place.
Install spark plugs.
Re-attach the spark plug wire to the spark plug.
On the GT-530, repeat the process for the other cylinder.
15
 Maintenance
3.10 MAJOR SERVICE MANUAL
To obtain a service manual for the generator, contact the near-
est Authorized Service Dealer. Make sure to identify the MODEL
NUMBER and SERIES.
3.11 DRIVE BELT
The engine drives the generator rotor by means of a pulley and
drive belt arrangement. Drive belt tension was properly adjusted
before the unit was shipped from the factory. If suspect that drive
belt tension is incorrect, contact an Authorized Service Dealer.
3.12 EXERCISING THE GENERATOR
The manufacturer recommends starting and operating the genera-
tor at least once every seven days. Let the unit run for at least 30
minutes to exercise the engine.
3.13 OUT OF SERVICE PROCEDURE
3.13.1 REMOVAL FROM SERVICE
If the generator cannot be exercised every seven days, and it is to
be out of service longer than 30 days, prepare the generator for
storage as follows:
1. Start the engine and let it warm up.
2. Close the fuel shutoff valve in the fuel supply line and allow
the unit to shut down.
3. While the engine is still warm from running, drain the oil
completely. Refill the crankcase with SAE 5W-30 oil having
API classification For Service SJ/SL.
4. Attach a tag to the engine indicating the viscosity and clas-
sification of the oil in the crankcase.
5. Remove the spark plug and pour two or three tablespoons of
clean, fresh engine oil into the spark plug threaded openings.
Reinstall and tighten the spark plug.
6. Remove the battery and store it in a cool, dry room on a
wooden board. Never store the battery on any concrete or
earthen floor.
7. Clean and wipe the entire generator.
16
3.13.2 RETURN TO SERVICE
To return the unit to service after storage, proceed as follows:
1. Check the tag on the engine for oil viscosity and classification.
Verify that the correct recommended oil is used in the engine
(see "Engine Oil Requirements"). If necessary, drain and refill
with the proper oil.
2. Check the state of the battery. Fill all cells of unsealed batter-
ies to the proper level with distilled water. DO NOT USE TAP
WATER IN THE BATTERY. Recharge the battery to 100 percent
state of charge, or, if defective, replace the battery.
3. Clean and wipe the entire generator.
4. Reconnect the battery. Observe battery polarity. Damage may
occur if the battery is connected incorrectly.
5. Turn OFF all electrical loads. Add fuel if necessary and then
start the engine.
6. Allow the unit to warm up thoroughly.
7. Apply electrical loads to at least 50 percent of the units rated
wattage capacity.
8. When the engine is thoroughly warmed up, shut it down.
9. The generator is now ready for service.
3.14 RV GENERATOR SERVICE
INTERVAL
1st 8 Hours,
then every 200 Hours ......................... Change Engine Oil/Filter
1st 50 Hours,
then every 500 Hours .................................. Adjust Valve Lash
200 Hours ..................................................Clean Spark Arrestor
200 Hours .................................Replace Paper Air Filter Element
400 Hours ......................................................Replace Fuel Filter
500 Hours ..................................................Replace Spark Plugs
 Part II - Installation Instructions

Part II
Installation
Instructions

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!
 Safety Rules
nDANGER: For fire safety, installation of a generator into a recreational vehicle must comply strictly with
article 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C Standard for Recreational
Vehicles (Part 3, Installation of Electrical Systems). In addition, installation must comply with the man-
ufacturers instructions and recommendations.
NOTICE TO INSTALLER
These Installation Instructions have been published by the manu-
facturer to aid in the installation of the products described in this
manual. The manufacturer assumes that installation personnel
are familiar with the procedures for installing such products, or
similar products manufactured. The manufacturer also assumes
that personnel have been trained in the recommended installation
procedures for these products and that such training includes (a)
use of common hand tools, (b) use of special tools, and (c) use of
any tools and/or equipment from other suppliers.
The manufacturer cannot possibly know of and advise the rec-
reational vehicle trade of all conceivable methods, procedures or
techniques by which to perform an installation. Nor can the manu-
facturer anticipate every possible hazard that might result from
each installation method, procedure or technique. The manufactur-
er has not undertaken any such wide evaluation. Therefore, people
who use a method, procedure or technique that the manufacturer
does not specifically recommend must first completely satisfy
themselves that their safety, the safety of the vehicle's occupants
and the product's safety is not endangered by the method, proce-
dure or technique selected.
Information, illustrations, specifications, etc., contained in these
Installation Instructions are based on the latest information avail-
able at the time of publication. Every effort has been expended
to be sure that such data is both accurate and current. However,
the manufacturer reserves the right to change, alter or otherwise
improve this product at any time without prior notice.
nDespite the safe design of this generator,
operating this equipment imprudently, neglect-
ing its maintenance or being careless can
cause possible injury or death. Permit only
responsible and capable persons to operate
or maintain this equipment.
these machines. Ensure all steps are taken to
Potentially lethal voltages are generated by
render the machine safe before attempting to
work on the generator.
nParts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
18
GENERAL HAZARDS
For safety reasons, the manufacturer recommends that the
installation, initial start-up and maintenance of this equipment
is carried out by an Authorized Service Dealer.
The generator engine releases DEADLY carbon monoxide gas
through its exhaust system. This dangerous gas, if breathed
in sufficient concentrations, can cause unconsciousness or
even death. Never operate the generator set with the vehicle
inside any garage or other enclosed area. Shut down the
generator and do not operate it until it has been inspected
and repaired.
DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM
IS LEAKING OR HAS BEEN DAMAGED.
SYMPTOMS OF CARBON MONOXIDE POISONING ARE (a)
inability to think coherently, (b) nausea, (c) vomiting,
(d) twitching muscles, (e) throbbing temples, (f) dizzi-
ness, (g) headaches, (h) weakness, and (i) sleepiness. IF
EXPERIENCING ANY OF THESE SYMPTOMS, MOVE INTO
FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET
MEDICAL HELP.
Never sleep in the vehicle while the genset is running unless
the vehicle has a working carbon monoxide detector. The
exhaust system must be installed in accordance with the
genset installation manual. Make sure there is ample fresh
air when operating the genset in a confined area.
Keep hands, feet, clothing, etc., away from drive belts, fans,
and other moving or hot parts. Never remove any drive belt or
fan guard while the unit is operating.
Adequate, unobstructed flow of cooling and ventilating air is
critical to correct generator operation and is required to expel
toxic fumes and fuel vapors from the generator compartment.
Without sufficient cooling airflow, the engine/generator quickly
overheats, which causes serious damage to the generator. Do
not alter the installation or permit even partial blockage of ven-
tilation provisions, as this can seriously affect safe operation of
the generator.
When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally
fatigued.
Before performing any maintenance on the generator, discon-
nect its battery cables to prevent accidental start up. Disconnect
the cable from the battery post indicated by a NEGATIVE, NEG
or () first. Reconnect that cable last.
Never use the generator or any of its parts as a step. Stepping
on the unit can stress and break parts, and may result in dan-
gerous operating conditions from leaking exhaust gases, fuel
leakage, oil leakage, etc.
Never insert any tool or other object through openings in the
generator interior, even if the unit is not running. Serious injury
or damage to the equipment could be done.

ELECTRICAL HAZARDS
The generator covered by this manual produces dangerous
electrical voltages and can cause fatal electrical shock. Avoid
contact with bare wires, terminals, connections, etc., while the
unit is running. Ensure all appropriate covers, guards and bar-
riers are in place before operating the generator. If work must
be done around an operating unit, stand on an insulated, dry
surface to reduce shock hazard.
Do not handle any kind of electrical device while stand-
ing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
During installation onto the vehicle, properly ground (bond) the
generator either by solid mounting to the vehicle frame or chas-
sis, or by means of an approved bonding conductor. DO NOT
connect the bonding conductor to any generator part that might
be removed or disassembled during routine maintenance. If
the grounding conductor must be replaced, use only a flexible
conductor that is of No. 8 American Wire Gauge (AWG) copper
wire minimum.
If the vehicle electrical circuits can be powered by any other
source of electricity (such as a dockside power receptacle),
there must be no possibility of connecting the different power
sources to the vehicle circuits at the same time. The dockside
(utility) power source must be positively isolated from the
vehicle circuits whenever the generator is operating. Failure to
isolate the vehicle circuits from the dockside power supply when
the generator is running may result in damage to the generator
or serious injury or death to dockside (utility) power workers due
to backfeed of electrical energy.
In case of accident caused by electric shock, immediately shut
down the source of electrical power. If this is not possible,
attempt to free the victim from the live conductor. AVOID DIRECT
CONTACT WITH THE VICTIM. Use a nonconducting implement,
such as a rope or board, to free the victim from the live conduc-
tor. If the victim is unconscious, apply first aid and get immediate
medical help.
Never wear jewelry when working on this equipment. Jewelry
can conduct electricity resulting in electric shock, or may get
caught in moving components causing injury.
Safety Rules
FIRE HAZARDS
For fire safety, the generator must be installed and maintained
properly. Installation always must comply with applicable
codes, standards, laws and regulations. Adhere strictly to local,
state and national electrical and building codes. Comply with
regulations the Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the generator is
installed in accordance with the manufacturers instructions
and recommendations. Following proper installation, do noth-
ing that might alter a safe installation and render the unit in
noncompliance with the aforementioned codes, standards,
laws and regulations.
Keep a fire extinguisher in the vehicle at all times. Extinguishers
rated ABC by the National Fire Protection Association are
appropriate for use on the recreational vehicle generator electrical
system. Keep the extinguisher properly charged and be familiar
with its use. If there are any questions pertaining to fire extin-
guishers, consult the local fire department.
EXPLOSION HAZARDS
Do not smoke around the generator. Wipe up any fuel or oil spills
immediately. Ensure that no combustible materials are left in the
generator compartment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surrounding the generator
clean and free from debris.
Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE.
Do not permit smoking, open flame, sparks or any source of
heat in the vicinity while handling gasoline. Comply with all laws
governing the storage and handling of gasoline.
Fuel lines must be properly installed and fastened, and free of
leaks. There must be no possibility of gasoline vapors entering
the vehicle interior.
It is required that an approved, flexible, nonconductive fuel line
between the generator fuel connection point and rigid fuel lines
be installed.
If the generator is equipped with a liquid propane (LP) gas fuel
system, install the unit so it complies with all codes, standards
and regulations pertaining to such systems. LP gas is highly
explosive. The gas tends to settle in low areas where even the
slightest spark can ignite it and cause an explosion. Do not
allow gas vapors to enter the vehicle.
19
 General Information

1.1 PURPOSE AND SCOPE OF THE 1.4 EQUIPMENT DESCRIPTION

Instructions and information in this section pertain to air-cooled
INSTALLATION INSTRUCTIONS generators. These generators are designed specifically for install-
These Installation Instructions have been prepared especially for ing in recreational vehicles. They operate 120-volt, single-phase,
the purpose of familiarizing installers and owners of the applicable 60-Hertz, AC electrical loads.
equipment with the product's installation requirements. Give seri-
ous consideration to all information and instructions in the manual,
both for safety and for continued reliable operation of the equip- 1.5 GENERATOR ENGINE
ment. OPERATING SPEED
Because of the different recreational vehicle models and the The generators revolving field (rotor) is driven by a two-cylinder,
variations between the models, it would be extremely difficult, if four-cycle engine through a pulley and drive belt arrangement. The
not impractical, to provide detailed instructions for every possible generator supplies 120 volts AC at 60 Hertz when the rotor is oper-
installation. For that reason, instructions and illustrations in this ating at 3,600 rpm. The drive belt arrangement allows the engine to
manual are general in nature. Illustrations are not intended to serve operate at a lower speed than the rotor.
as detailed installation blueprints.
The installation should comply strictly with all applicable codes, 1.6 GENERATOR AC
standards and regulations pertaining to the installation and use of CONNECTION SYSTEM
this product. If any portion of this manual appears to be in conflict These air-cooled generator sets are equipped with dual stator AC
with such codes, standards or regulations, the applicable codes, power windings. These two stator windings supply electrical power
standards or regulations must take precedence over the manual. to customer electrical loads by means of a dual 2-wire connection
system.
1.2 SAFETY Generators may be installed to provide the following outputs:
Before handling, installing, operating or servicing this equipment, 1. 120 VAC loads only two loads each, with a maximum total
carefully read the Notice to Installer and Safety Rules. Comply wattage requirement equal to half of the generators rated
with all safety rules to prevent death, personal injury or damage to power output (in watts), and 120V across the generator out-
equipment and/or property. Stress safety to all installers, operators put terminals (see Fig. 1.1).
and service technicians who work on this equipment.
2. 120/240 VAC loads one load with a maximum total wattage
requirement equal to the generators rated power output, and
1.3 STANDARDS BOOKLETS 240V across the generator output terminals; or two separate
Installation, use and servicing of this equipment should comply loads, each with a maximum total wattage requirement equal
strictly with published standards, as well as the manufacturer's to half of the generators rated power output (in watts), and
recommendations. The following standards booklets (latest revi- 120V across the generator output terminals (see Fig. 1.3).
sion) are available from the sources indicated: Figure 1.1 Connection for 120 Volts Only
1. NFPA Standard 501C, Standard for Recreational Vehicles,
available from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
2. NFPA 70, NFPA Handbook of the National Electric Code,
available same as Item 1.
3. ANSI C1-1975 and ANSI 119.2-1975, available from the
American National Standards Institute, 1430 Broadway, New
York, NY 10018.
4. ANSI A119.2/RVIA EGS-1, available from the Recreational
Vehicle Association, 1896 Preston White Drive, Reston, VA
22090.
5. California Administrative Code, Title 25, available from the
State of California, Documents Section, P.O. Box 1015, North
Highlands, CA 95660.
6. CSA Electrical Bulletin 946, available from the Canadian
Standards Association, Housing and Constructions Materials
Section, 178 Rexdale Boulevard, Rexdale, Ontario, Canada,
M9W 1R3.

20
 Installation

Figure 1.2 - Major Features and Dimensions (Drawing No. 0G5519-D)

21
 Installation

Figure 1.3 - Connection for 120/240 Volts The location must provide sufficient room to allow minimum
clearances as outlined in "Generator Compartments". If sound
T1 insulation is to be used on the compartment walls and ceiling,
CB1
RED the minimum recommended applies to the space between the
generator and such insulation.
The location must provide adequate cooling and ventilating
airflow for the generator without a great deal of work and
expense.
If mounting the generator in an enclosed compartment, the base
T2 of the generator must rest flat on the floor without any gaps.
WHITE When using a suspended mounting system, ensure the base of
the generator is flush with the surrounding bodywork. If the unit
is mounted higher in the structure, heated air may recirculate
into the generator causing it to overheat.

2.1.2 GENERATOR SUPPORT

CB2 T3 The generator must be securely attached to a metal framework that
BLACK
GROUNDED NEUTRAL
has been made part of the vehicle frame structure by bolting or
STATOR POWER
WINDINGS welding. The metal framework on which the generator will rest and
which will restrain the generator set should consist of at least two
horizontal beams. These beams should consist of (a) 1-1/2-inch
The AC connection system on air-cooled generators uses a square, 11-gauge steel tubing OR (b) 1-1/2-inch, 11-gauge angle
GROUNDED neutral. iron. A typical supporting frame with horizontal support tubing, is
A separate green ground wire is connected to the recreational shown in Figure 2.1.
vehicles junction box.
Total load connected across T1 (Red) to T2 (White), and T3 Figure 2.1 Typical Horizontal Support Frame
(Black) to T2 (White), must not exceed rating for the specific
generator (see "Generator Specifications").
NOTE:
Do NOT connect loads in excess of circuit breaker ratings.

2.1 LOCATION AND SUPPORT

2.1.1 GENERATOR LOCATION
NOTE
Be sure the installation complies with all standards and codes
listed in the "Standards Booklets" section of this manual.
The most desirable location for the generator set is between the
vehicle's main frame members. However, this is seldom possible.
Most units must be installed on the side of the vehicle and are
difficult to reinforce.
Many recreational vehicles have been factory equipped with an
area for the generator set. Some vehicles may even have a genera-
tor compartment provided by the vehicle manufacturer.
Plan the generator location based on the following:
The generator set must be installed on a framework that is
part of the recreational vehicle, as outlined in the "Generator
Support" section.
The location must provide an access opening that is large
enough to permit generator removal (unless the generator is to
be removed from underneath the supporting framework).
The location must provide easy access to frequently serviced
components, such as filters, oil drains, spark plugs and other
common maintenance parts.
The generator can be installed so that it sits on top of the horizontal
support tubing if the vehicle design permits. Another method is
to suspend the generator below the horizontal support tubing by
means of suitable, structurally sound metal framework. The fol-
lowing general rules apply:
Vehicle construction MUST be capable of supporting the weight
of the generator.
Whether the generator is mounted above the horizontal support
tubing or suspended below the tubing, the supporting frame
used must be structurally sound.
If the generator cannot be bolted directly to the supporting
frame or support tubing, consider using additional tubing,
angle brackets or other supports to give the supporting frame
sufficient strength.

22
 Installation

2.1.3 SUSPENDED MOUNTING 2.2 GENERATOR COMPARTMENTS

If planning to suspend the generator below the horizontal sup-
port tubing, the suspension method to use with the vehicle frame
members must (a) be able to support the weight of the generator
AND (b) provide sufficient restraint for the generator. One typical
suspended mounting system is shown in Figure 2.2. The location
of a suspended mounting system must be carefully planned, keep-
ing the following general rules in mind:
Protect the generator against road splash and debris. Baffles or
splash guards may be required to protect certain areas of the
generator. To make sure the generator is adequately protected,
road test the installation through mud, water and slush.
Figure 2.2 Typical Suspended Mounting System
Whether the generator set is being installed inside a compartment
specifically manufactured to house a generator or inside a compart-
ment that the installer constructs, the compartment MUST meet
certain specifications as outlined in the following sections:
2.2.1 COMPARTMENT SIZE
Plan the compartment size carefully. Provide a minimum clearance
of 1/2 inch (13 mm) on the front top, sides, and from the back for
air circulation AFTER the compartment has been lined with metal
and sound insulation (Figure 2.4).
NOTE:
Refer to Figure 1.2 Major Features and Dimensions.
Figure 2.4 Clearances

Plywood
Compartment
1/2" Clearance on Top
1/2" Clearance
in Back

1/2" Each Side

The installer must make certain that the selected location will
1/2"
permit adequate cooling and ventilating airflow to be supplied. Insulation
in Front ed
nd
m me )
eco 12"
2.1.4 GENERATOR RESTRAINT r
e R um
anc inim
a
Cle w (M
Use four 3/8"-16 hardened steel bolts (Grade 5) to fasten the 18" Belo
generator to the supporting frame or the support tubing. These
bolts must pass through (a) the generator mounting base, (b) the
compartment floor (if a compartment is used) and (c) the support-
ing framework (Figure 2.3). All bolts must be long enough so that
when tight, at least three threads are visible past the retaining lock
nuts. Refer to "Generator Compartments" for the location of the 2.2.2 COMPARTMENT CONSTRUCTION
generator mounting holes. Torque Bolts to 31 ft./lbs.. The generator compartment should be either constructed of, or
lined with, 26-gauge galvanized steel.
Figure 2.3 Typical Generator Restraint NOTE:
Aluminum is NOT an acceptable alternative to galvanized steel
due to aluminums low melting point.
If the compartment is lined with galvanized steel, it may be
constructed of any material. The manufacturer recommends
that the compartment be constructed of 1/2-inch thick plywood
(not strandboard), with the floor made of a double thickness of
1/2-inch plywood with the grain of the wood at cross section
for added strength (Figure 2.5).
If constructing a compartment, line the exterior (underside) of
the compartment floor with 26-gauge galvanized steel.
All seams, splices and joints of the compartment walls (unless
vapor tight by design) should be caulked to prevent poison-
ous, flammable or explosive vapors from entering the vehicle
interior.

23
 Installation
Figure 2.5 Typical Compartment Construction
NOTE:
Caulking must be done so that the caulking material will stay in
place permanently. Pressing such materials as putty tape onto
joints and seams is not acceptable. A high quality silicone rub-
ber base sealant is recommended.
Holes and openings made in the compartment walls to allow for
the passage of electrical conduit, conductors, hoses, cables,
etc., into the vehicle living area must be sealed vapor tight with
silicone rubber base sealant.
If flexible metal conduit is used, it must be sealed internally at
the end where it terminates inside the compartments electrical
junction box.
NOTE:
Flexible metal conduit, due to its unique construction, is NOT
vapor tight along its entire length.
Seams and joints of the galvanized steel (whether used as a liner
or for the compartment itself) must be lapped and mechanically
secured. Such seams may be manufactured, welded, bolted,
riveted or screwed. Manufactured lock seams are shown in
Figure 2.6. Installer constructed compartments typically utilize
a standard lap joint.
After the compartment has been metal lined and vapor
sealed, line the compartment interior walls and ceiling with an
approved, nonflammable sound insulating material. See "Sound
Insulating Materials".
24
Figure 2.6 Types of Lock Seams
above or around the compartment. Heat,
Do not install any flammable material directly
transferred through the compartment struc-
ture, may be sufficient to ignite, char or dis-
color seat cushions, fiberboard and other
flammable materials. Use approved nonflam-
mable insulating materials in high tempera-
ture areas.
2.2.3 SOUND INSULATING MATERIALS
Once installers have determined that a compartment is properly
constructed and metal lined, they can add acoustical material.
This may include additional sealant or insulating material, to reflect
noise away from the vehicle interior.
Sound insulating materials should be of a nonflammable type. One
excellent insulating material is a 1-inch (25 mm) thick fiberglass
having a 2-pound density. When fiberglass is used, its coated side
should face toward the compartment interior.
bent material on the compartment floor inte-
Do not install sound insulation or any absor-
rior. Such materials will become soaked with
combustible or explosive vapors and liquids
and will become a fire hazard.
Using a combination of sound insulating materials can often
reduce noise more effectively than a single material. For example,
a sheet of lead or visco-elastic material, along with a layer of other
acoustical material, is more effective than when a single material
is used.

2.2.4 ACOUSTICS
For additional noise abatement, the installer may wish to consider
the following:
Using special sound insulating materials.
Construction of a special noise abatement compartment.
NOTE:
Any method used to reduce noise must not adversely affect the
flow of cooling and ventilating air into or out of the compart-
ment.
In addition to the effective use of sound insulating materials,
construction of a special noise abatement compartment might be
considered to reduce noise levels. Such a compartment might be
constructed as follows (Figure 2.7):
Use 5/8-inch thick or 3/4-inch thick plywood in the compart-
ment.
Construct the compartment floor of a double thickness of 5/8-
inch or 3/4-inch plywood.
Line the compartment interior walls and floor, as well as the
underside of the floor, with 26-gauge galvanized steel.
Vapor seal all compartment seams and joints.
Over the galvanized steel lining, install a combination of acousti-
cal materials as mentioned in "Sound Insulating Materials".
any insulation or other absorbent materials
To prevent fire or explosion, do not install
on the interior or underside of the compart-
ment floor.
Seal all compartment door edges to prevent noise leakage
around the door perimeter.
Figure 2.7 Typical Noise Abatement
Line the compartment door interior (except for air openings)
with suitable, fireproof sound insulation (such as 1-inch (25
mm) thick fiberglass with a 2-pound density).
Installation
2.2.5 COMPARTMENT FLOOR CUTOUTS
Provide openings in the generator compartment for the following
items (Figure 2.9):
Engine exhaust and cooling air outlets
Generator cooling air inlet
Four holes for passage of generator mounting bolts. See
"Generator Restraint".
nFuel lines and exhaust piping must not pen-
etrate into the vehicle living area.
2.3 COOLING AND VENTILATING
AIR
It is absolutely essential that an adequate flow of air for cooling,
ventilating and engine combustion be supplied to the generator set.
Without sufficient airflow, the engine/generator quickly overheats.
Such overheating can cause serious operating difficulties and also
may cause fire and personal injury. The installer must make sure
that sufficient air is available to the generator for cooling, ventilat-
ing and combustion. The installer also must provide for a path for
exhausting the cooling air to the exterior of a compartment, if so
equipped.
or permit such air to enter the vehicle inte-
Never use discharged cooling air for heating
rior. This air contains deadly carbon monox-
ide gas and other poisonous, flammable or
explosive gases.
2.3.1 GENERATOR AIRFLOW
Engine operation drives cooling fans for the two-stage cooling
air system. A pressure fan draws cooling air into the top of the
generator (Figure 2.8). This airflow cools the engine/generator and
electronic components. The second part of the cooling system, a
suction fan, draws air that is heated from a hot engine into a col-
lector pan at the base of the unit. This heated air (although cooler
than exhaust muffler) is then deflected out the bottom toward the
ground.
Figure 2.8 Airflow Through Engine/Generator
COOLING AIR IN ENGINE AIR IN
COOLING
AIR OUT
25
Installation

Figure 2.9 Compartment Floor Cutout (Drawing 0G4432-A)

26

6.3.2 TESTING THE INSTALLATION
The manufacturer recommends testing the installation to be sure
adequate cooling airflow is available to the unit before placing the
unit into service. If the unit shows signs of overheating, enlarge the
air openings. Never place a unit into service until absolutely certain
that cooling and ventilation is adequate.
NOTE:
The installation must be tested, especially if bringing in air from
below the generator set.
2.4 GASOLINE FUEL SYSTEM
Gasoline is highly flammable, and its vapors
are explosive. Comply with all codes, stan-
dards and regulations pertaining to gasoline
fuel systems used in recreational vehicle
generators. Properly install and maintain
the fuel system and keep it entirely free of
leaks. Gasoline vapors must not enter the
vehicle interior.
The installation of a gasoline fuel system (Figure 2.10) for a
recreational vehicle generator set must comply with applicable
codes, standards and regulations. The entire fuel system must be
completely free of leaks. There must be no possibility of gasoline
vapors entering the vehicle interior.
Figure 2.10 Generator Fuel System
a, b e d
Factory installed generator fuel system components include (a)
fuel filter, (b) 12-volt DC electric pump, (c) engine carburetor, and
(d) interconnecting lines and fittings, (e) evaporative port. Connect
a fuel supply line to the fuel filter inlet. Use a flexible length of
approved fuel hose between the fuel filter inlet connection and
rigid fuel lines.
2.4.1 FUEL TANK
Either the generator must share the vehicle engine's fuel tank, or a
separate fuel tank for the generator set must be installed. All fuel
tanks installed on the vehicle must be constructed, installed and
restrained so they comply with applicable codes, standards and
regulations. The generator has an evaporative emissions port to
evacuate accumulated gasoline vapors when necessary.
Installation
If the generator is to share the vehicle engine's tank, separate
fuel pickup tubes are required for the engine and the generator.
The manufacturer recommends that the fuel pickup tube be two
to three inches (51 to 76 mm) shorter than the vehicle engine's
pickup tube. This prevents the generator from depleting the entire
fuel supply during prolonged generator operating periods.
Gasoline generators are equipped with an Evaporative Emissions
Port that may be used in conjunction with a certified fuel system
where required by law.
nDo NOT tee the generator fuel supply line
into the vehicle engine fuel supply line. If
this is done, the generator will be starved of
fuel when both engines are operating at the
same time. Also, while the vehicle engine is
not running, generator operation may drain
the vehicle engine supply line, making it dif-
ficult to start the vehicle engine.
2.4.2 GENERATOR FUEL SUPPLY LINE
2.4.2.1 Rigid Fuel Lines
Those lines used to supply fuel from a tank to the generator must
comply with applicable codes, standards and regulations. The fol-
lowing general rules apply to rigid fuel lines:
Rigid lines should be of annealed, seamless, drawn aluminum
or steel.
Lines and fittings must comply with SAE J512F, Standard
Automotive Fittings, or with ANSI B126.26 (latest edition).
Route the fuel line so that at least 2 inches (51 mm) of clear-
ance is maintained between the line and any exhaust system
parts.
Do not attach electrical wiring to fuel lines. Route the wiring so
it cannot come into contact with any fuel line.
Route fuel lines so if they leak, fuel does not drip onto any
electrical or exhaust system parts.
Use nonferrous metal straps without sharp edges to secure
fuel lines.
2.4.2.2 Flexible Fuel Line
Use an approved flexible length of fuel hose between the generator
fuel inlet connection and rigid fuel lines. This prevents breaking of
the line caused by vibration, shifting, settling or movement. The
following rules apply:
The flexible hose must comply with SAE J30R7, Standard for
Fuel and Oil Hose. It must be approved for use with gasoline
and low permeability.
The hose should be at least 6 inches (152 mm) longer than
is needed to prevent the hose from rupturing if the generator
shifts or settles.
27
 Installation

2.5 EXHAUST SYSTEM Figure 2.11 - Spark Arrestor

The generator exhaust system must be safely and properly
installed. Only approved mufflers and other exhaust system parts
must be used. A properly installed exhaust system must be vapor
tight, quiet and completely safe.

TAILPIPE
P/N 0E0683
nThe generator engine gives off DEADLY
carbon monoxide gas through its exhaust
system. This dangerous gas, if breathed in
sufficient concentrations, can cause uncon-
sciousness or even death. Never operate
the generator set with the vehicle inside SPARK ARRRESTOR
any garage or other enclosed area. DO SCREEN P/N 089680
NOT OPERATE THE GENERATOR IF THE
EXHAUST SYSTEM IS LEAKING OR HAS RETAINING
BEEN DAMAGED. SYMPTOMS OF CARBON SCREW P/N 056892
MONOXIDE POISONING ARE (a) inability to
think coherently; (b) vomiting; (c) twitch-
ing muscles; (d) throbbing temples; (e) Figure 2.12 Spark Arrestor Installation
dizziness; (f) headaches; (g) weakness;
and (h) sleepiness. IF FEELING ANY OF
THESE SYMPTOMS, MOVE INTO FRESH AIR
IMMEDIATELY. IF SYMPTOMS PERSIST, GET
MEDICAL HELP. Do not operate the generator
until its exhaust system has been inspected
and properly repaired.

nNever tee the generator engine exhaust pipe

into the vehicle engine exhaust piping. This
causes excessive back pressure on the gen-
erator engine. Also, water from one engine
can damage the other engine.
2.5.1 MUFFLERS AND SPARK ARRESTORS
This muffler meets code and standard requirements of the U.S.
Forest Service. Use only mufflers and parts approved by the
manufacturer. Any person(s) installing an unapproved muffler,
or an unapproved exhaust system part, or modifying an exhaust
system in any way that might cause a hazard, is liable for any
damage, injury or warranty expense that might be caused by such
unapproved installation or modification.
Failure to provide and maintain a spark arrestor may be in violation
of the law. If this generator is used on any forest covered, brush
covered or grass covered unimproved land, a spark arrestor must
be provided. The vehicle owner or operator must maintain this
device in good condition. In the state of California, the preceding
is required by law (Section 4442 of the California Public Resources
Code). Other states may have similar laws. Federal laws apply on
federal lands.
When installing/replacing the tailpipe or spark arrestor compo-
nents, verify that the tailpipe has a hole to securely fasten the
spark arrestor components (see Figures 2.11 and 2.12). Use only
manufacturer supplied hardware. Substitution of parts may cause
damage to the screen or a loose fit to the tailpipe.
28
2.5.2 EXHAUST SYSTEM SAFETY
Maintain a clearance of at least 3 inches (76 mm) between
exhaust system parts and any combustible material (such as
wood, felt, cotton, organic fibers or other like material). If the
3-inch (76 mm) clearance cannot be maintained, locate, insu-
late or shield the exhaust part(s) so that the temperature of any
combustible material is not raised more than 117 F (65 C)
above the ambient air temperature.
Extend the exhaust system at least 1 inch (25 mm) past the
outer edge of the vehicle. Do not terminate the exhaust system
under the vehicle.
Terminate the exhaust tailpipe such that exhaust gases will not
be drawn back into the generator compartment and recircu-
lated.
If there is any possibility of the tailpipe or muffler being dam-
aged, protect these damage-prone areas by means of a protec-
tive device (such as a skid bar).
Install the generator exhaust system according to safe automo-
tive practices.
Use enough exhaust system hangers to prevent any part of the
system from being dislocated.
Use exhaust system parts recommended by the manufacturer.
Using unapproved exhaust mufflers and exhaust system parts
is the responsibility of the person(s) installing such unauthor-
ized parts.
 Installation

Do not terminate the exhaust system under any opening, win- From the junction box, route power supply wires through
dow or vent that can be opened or is not permanently sealed approved conduit to either (a) double-pole, double-throw trans-
from the vehicle interior. fer switch, or (b) approved isolation receptacle. Connecting to
Exhaust piping must be large enough to prevent excessive back a transfer switch or isolation receptacle must prevent vehicle
pressure on the generator engine. electrical circuits from being connected to two different power
Never tee the generator engine exhaust pipe into the vehicle supplies at the same time (such as generator and dockside
engine exhaust piping. This causes excessive back pressure on power).
the generator engine. Also, water from one engine can damage Conductors must be rated 221 F (105 C) or must be of a
the other engine. larger conductor size.
Plan exhaust system installation carefully. Comply with all appli-
cable codes, standards and regulations. 2.6.3 GENERATOR AC CONNECTIONS
Generator AC output leads T1 (red), T2 (white) and T3 (black)
2.6 ELECTRICAL CONNECTIONS come out of the generator as shown in Figure 2.13. Leads T1 (red)
The following general rules apply to electrical connections in a and T3 (black) are hot, while T2 (white) is the grounded neutral
recreational vehicle: lead. There is also a green lead that connects to ground in the
junction box of the recreational vehicle.
Qualified electricians who are familiar with applicable codes,
standards and regulations should install electrical wiring.
The wiring should comply with codes, standards and regula- Figure 2.13 Generator AC Output Leads
tions. The National Electrical Code (NFPA 70), and state and
local codes apply.
Switches and circuit breakers should be of a type approved for
use in recreational vehicles and must be mounted and installed
to prevent damage from road shock.
Wiring must be of adequate size, have approved insulative
qualities and be properly supported.
Conduit and wire openings into the generator compartment
(if used) must be vapor-sealed to prevent entry of flammable,
explosive or poisonous gases into the vehicle.

2.6.1 ELECTRICAL JUNCTION BOX

Install an approved, square electrical junction box with a blank
cover on the interior or exterior wall of the area planned for installa-
tion of the generator (NOT on the generator). Route the generator's
AC output leads into this junction box through approved flexible
conduit. This is the point of first termination for generator AC
output leads.
T3
T2

AC Output Leads T1

2.6.2 WIRING Green

(Ground)

Wiring should be of stranded copper to reduce the chance that

vibration may cause breakage.
Wire gauge size should be large enough to handle at least 115
percent of the installed generator's rated maximum current.
If neutral conductors are used, they must be the same size as
other leg wires.
Route power supply conductors from generator AC output leads
T1 (red), T2 (white), T3 (black) and the green ground wire
through approved flexible conduit to the electrical junction box
on the compartment wall.
If flexible metal conduit is used between the generator and the
compartment junction box, the conduit end that terminates the
compartment junction box must be vapor-sealed. Flexible metal
conduit is NOT vapor tight along its entire length.
4500 Watts
Line T1 (black) to T2 (white) is protected by circuit breaker a
(CB1). Use this line to neutral connection to operate 120 volt,
single-phase, 60 Hz, AC loads.
5500 and 6500 Watts
Line T1 (red) to T2 (white) is protected against overload by a cir-
cuit breaker (CB1). Use this line-to-neutral connection separately
to operate 120-volt, single-phase, 60 Hertz, AC loads. Line T3
(black) to T2 (white) also is protected against overload by a circuit
breaker (CB2). Use this line-to-neutral connection separately to
operate similar loads. However, be sure the total unit load does not
exceed the maximum rating of the generator. The neutral line (T2,
white) on all units is a grounded neutral.

29
 Installation

2.7.1 RECOMMENDED BATTERY

Install a battery that meets the following requirements:
of any circuit breaker rating or problems will
Do NOT connect electrical loads in excess
The battery must be a 12-volt, automotive type storage bat-
develop with circuit breaker tripping, which tery.
causes a loss of AC output. Also, do NOT For prevailing ambient temperatures above 32 F (0 C), use
exceed the generator's rated wattage capac- a battery rated 70 amp-hours and capable of delivering 400
ity. Add the watts or amperes of all lighting, cold-cranking amperes.
appliance, tool and motor loads the generator For prevailing ambient temperatures below 32 F (0 C), use
will operate at one time. This total should be a battery rated 95 amp-hours and capable of delivering 400
less than the unit's rated wattage/amperage cold-cranking amperes.
capacity. NOTE:
2.6.4 CONDUIT If the battery is to be used to power other vehicle accessories,
as well as start the generator, a battery with a larger capacity
Route the connections between the generator and the junction box may be needed.
through approved, flexible conduit. The following general rules
apply:
2.7.2 BATTERY CABLES
Cut wiring to the required length and allow extra wire for junc-
tion box connections. Using battery cables that are too long or too small in diameter
may cause a drop in voltage, which causes starting problems. For
Carefully prepare conduit ends to prevent sharp edges from
the best cold weather starting, the voltage drop between battery
cutting through wiring insulation.
terminals and the generator connection point should not exceed
Route conduit so it does not interfere with generator move- 0.12 volts per 100 amperes of cranking current.
ment.
If using metallic conduit, vapor seal the end of the conduit These generators are rated at about 100 DC amperes of cranking
where it enters the junction box. Do this because flexible metal- current.
lic conduit is not vapor proof along its entire length. Select battery cables based on (a) cable length and (b) prevail-
ing ambient temperatures. Generally, the longer the cable and the
2.6.5 ISOLATING DIFFERENT POWER SOURCES colder the weather, the larger the cable size must be, as shown in
Connections from the junction box must terminate in a double- the chart.
pole, double-throw transfer switch (Figure 2.14). An alternate
method for isolating different power sources is by using an isolat- CABLE LENGTH in Feet (meters) CABLE SIZE
ing receptacle (Figure 2.15). Whichever method is used, be certain 0 to 10 (0 to 3) 2*
that both power sources are NOT connected at the same time. 11 to 15 (3.4 to 4.5) 0
16 to 20 (4.5 to 6) 000
2.6.6 POWER SUPPLY CORD
*For warm weather, use No. 2 cable up to 20 feet.
The power supply cord must comply with all applicable codes,
standards and regulations. It must be large enough to handle the NOTE:
full amperage to which it will be subjected.
Where a minimum of 1025 CCA (cold cranking amps) battery
current is available, up to 30 feet of AWG #2 battery cable is
2.6.7 GROUND FAULT CIRCUIT permitted.
INTERRUPTERS
The National Electrical Code (NFPA 70, article 551) requires that 2.7.3 BATTERY CABLE CONNECTIONS
ground fault circuit interrupters (GFCIs) on all external and some 1. Connect the battery cable from the battery post or terminal
internal electrical receptacles be installed. Contact the manufac- indicated by a POSITIVE, POS or (+) to the lug on the starter
turer or dealer for recommendations. contactor (Figure 2.16).
NOTE:
2.7 BATTERY INSTALLATION Check to be sure the battery cable boot for the starter cable has
NOTE: been installed.
This generator is not equipped with an internal battery charger. 2. Connect the battery cable from the battery post indicated by a
It is intended for use in systems where an external battery char- NEGATIVE, NEG or (-) to the frame ground connection (Figure
ger is installed by the RV O.E.M. or an aftermarket installer. 2.16).
3. Connect cables so the connectors are clean and tight.

30
 Installation

Figure 2.14 Typical Transfer Switch Isolation Method

Figure 2.15 Typical Installation With Isolation Receptacle

31
 Installation

Figure 2.16 Connecting Battery Cables Figure 2.17 Remote Panel Plug-in Receptacle

Positive Cable

Battery

Chasis Ground
Negative Cable

2.7.4 BATTERY COMPARTMENT

Install the generator battery in its own, vented compartment. Place
the battery compartment away from any source of heat, sparks
or flame.
Provide ventilation openings in the battery compartment. The
minimum size of openings should be two (2) square inches at
the top of the compartment. Mount the battery on a strong, rigid
supporting structure, where leaks and spills of battery fluid will not
cause damage.

2.8 OPTIONAL ACCESSORIES

A plug-in receptacle (Figure 2.17) is provided on the generator set.
Use this receptacle to connect an optional remote-mounted start/
stop panel to the generator. Installation of such a panel will permit
starting and stopping the generator engine from any convenient
location inside the vehicle.

2.8.1 REMOTE PANEL MODELS

The remote panels mount a rocker type start/stop switch, a
Generator Run advisory lamp and an hourmeter. The hourmeter
should be used in conjunction with the maintenance operations
found in Part I of this manual.

WIRE NO. WIRE COLOR FUNCTION

0 Black Ground
14 Blue Engine Run Signal
712 Blue 12 VDC
17 Brown/White Start
18 Brown/Black Stop

32

3.1 POST INSTALLATION TESTS
The air-cooled generator set was factory tested and adjusted. It
should not be necessary to adjust the unit any further except under
special circumstances.
Do not make any unnecessary adjustments.
n Factory settings are correct for most applica-
tions. When making adjustments, however,
be careful to avoid overspeeding the engine.
3.2 BEFORE INITIAL START-UP
Before starting, complete the following:
1. Check the engine crankcase oil level and, if necessary, fill to
the dipstick FULL mark (cross-hatched area) with the rec-
ommended oil. Do not fill above the FULL mark.
2. Check the fuel supply. Gas fuel lines must have been properly
purged and leak tested in accordance with applicable fuel
codes. All fuel shutoff valves in the fuel supply lines must be
open.
3.3 INITIAL START
When certain that the unit has been properly installed and prepared
for use, start the engine as follows:
1. Turn off all electrical loads. Do this by setting the generators
main circuit breakers to their OFF (or open) position.
2. Refer to Part I, Starting the Generator, for cranking and
starting instructions. The engine may require more cranking
for initial starting since the fuel lines have to be primed (use
of the primer switch will shorten this time).
3. Let the engine warm up for about five minutes to allow internal
temperatures to stabilize.
4. Carefully inspect the engine/generator for fuel, oil and exhaust
system leaks. Before proceeding to the next step, correct any
leakage immediately.
Post Installation
5. When all tests and adjustments at no-load are completed,
apply electrical loads and check for proper operation under
load (see "Testing Under Load"). Run the unit at least 30 min-
utes with loads applied.
6. Turn off all electrical loads by setting the generators main
circuit breakers to their OFF (or open) position.
7. Let the unit run at no-load for a few minutes to stabilize
internal engine/generator temperatures. Then, shut down the
engine.
NOTE:
The generator set was thoroughly tested and adjusted at the fac-
tory before shipping. No additional adjustment should be neces-
sary. Only qualified service technicians who have been trained
should perform adjustments outlined in this manual.
3.4 TESTING UNDER LOAD
Apply electrical loads equal to about 75 to 100 percent of the unit's
rated wattage/amperage capacity.
Let the unit run at least 30 minutes with load applied. During this
part of the test, check that the unit is not running excessively hot
and that adequate cooling airflow is available. Do not allow the unit
to overheat during prolonged operation.
NOTE:
The generator engine is equipped with a high temperature
switch. The switch has normally open (N.O.) contacts. When the
engine temperature is too high, switch contacts close, and the
engine shuts down automatically.
THE MANUFACTURER RECOMMENDS THAT THE GENERATOR BE
TESTED FOR ADEQUATE COOLING.
33
 Post Installation
3.5 INSTALLATION CHECKLIST
LOCATION AND SUPPORT
Generator is properly located.
Generator is properly supported.
Generator is properly restrained.
GENERATOR COMPARTMENT
Compartment construction is proper.
Holes/Openings are vapor-sealed.
Compartment size is correct.
Compartment is vapor-sealed.
Sound insulation is correct.
Floor cutouts are properly completed.
COOLING AND VENTILATING AIR
Airflow is adequate.
Air inlet opening is correct.
Compensate for restrictions.
Check that installation has been tested.
GASOLINE FUEL SYSTEM
Fuel tank complies with all applicable codes.
Fuel system is properly installed and checked for
leaks.
EXHAUST SYSTEM
Exhaust system complies with all applicable codes.
Exhaust system is properly and safely installed.
DATE OF INSTALLATION _________________________________________________
NAME OF INSTALLER ____________________________________________________
SIGNATURE OF INSTALLER _____________________________________________
34
ELECTRICAL CONNECTIONS
Connections comply with local code requirements
and all National Electrical Codes.
Junction box is properly installed.
Wiring meets all standards.
All connections are correct.
Conduit is properly installed and sealed.
Generator is properly bonded to the vehicle.
Generator is always isolated from other power
sources.
BATTERY INSTALLATION
Recommended battery is installed.
Recommended cables are installed.
Cables are clean and tight.
Cables are connected properly.
Proper ventilation is provided.
Terminals are coated with anti-corrosion grease, and
terminal covers are positioned.
OPTIONAL ACCESSORIES
Check that remote start/stop panels (if used) are
installed properly.
Check that hourmeter kit (if used) is installed
properly.
Check that any other options and accessories (if
used) are installed properly.
POST INSTALLATION TESTS
Check that all tests are completed properly.
 Troubleshooting

4.1 TROUBLESHOOTING GUIDE

Problem Cause Correction
Engine wont crank. 1. 7.5 amp fuse blown. 1. Replace blown fuse.
2. Loose, or corroded or defective 2. Tighten, clean or replace,
battery cable(s). as necessary.
3. Battery is discharged or defective. 3. Recharge or replace battery.
4. Defective Start/Stop switch. 4. Replace switch.
5. Defective starter contactor. 5. Replace starter contactor.
6. Defective starter motor. 6. Replace starter motor.
7. Defective Engine Control Board 7. Contact an authorized service dealer.

Engine cranks, won't start. 1. Out of fuel. 1. Refill fuel tank.

2. Fuel pump not operating. 2. Repair or replace pump.
3. Automatic choke not operating properly. 3. Repair, replace or adjust.
4. Engine is flooded. 4. Wait 5-10 minutes; try again.
5. Fuel filter is clogged. 5. Replace filter if clogged.
6. Engine spark plugs defective. 6. Clean, regap or replace as needed.
7. Bad ignition magneto on engine. 7. Replace if defective.
8. Bad carburetor. 8. Adjust, repair or replace.
9. Dirty air cleaner. 9. Clean or replace as needed.

Engine starts hard, runs rough. 1. Dirty engine air cleaner. 1. Clean or replace as needed.
2. Automatic choke is sticking. 2. Free choke linkage as needed.
3. Defective spark plugs. 3. Clean, regap or replace.
4. Defective ignition magneto. 4. Replace it if defective.

Engine starts, then shuts down. 1. Engine oil level is low. 1. Add oil as needed.
2. Bad low oil pressure switch. 2. Replace, if bad.
3. Defective high temp switch. 3. Replace, if bad.
4. Water in fuel. 4. Drain fuel tank and refill.
5. Defective remote harness. 5. Disconnect remote harness. Contact
authorised service facility.

No AC output voltage. 1. Main breaker(s) open. 1. Close main breaker(s).

2. Transfer switch (if so equipped) is 2. Reset transfer switch.
set to wrong position.
3. Failure in vehicle electrical system. 3. See vehicle manual.
4. Generator component failure. 4. Contact an authorized service facility.

35
Electrical Data Wiring Diagram Drawing No. 0G4221-C

36
Wiring Diagram Drawing No. 0G4221-C Electrical Data

37
Electrical Data Wiring Diagram Drawing No. 0H3633-A

38
Wiring Diagram Drawing No. 0H3633-A Electrical Data

39
Exploded Views & Parts Lists Enclosure Drawing No. 0G3881-F

40
 Enclosure Drawing No. 0G3881-F Exploded Views & Parts Lists

ITEM PART NO. QTY. DESCRIPTION

1 0G3396 1 ENCLOSURE DOOR

2 0C5644 2 SLIDE LATCH, FLUSH
3 0G5236 1 FOAM ENCLOSURE DOOR
4 0D3700 23 NUT FLANGE M6-1.0 NYLOK
5 0G3401 1 DUCT, AIR IN DOOR
6 0G4077 1 GROMMET, OIL FILTER
7 0G4433 1 U CHANNEL 1/8
8 0G3377 1 TRAY, 530 RV
9 0G3431 1 GASKET AIR IN BOTTOM DUCT
10 0F9199 1 PLUG PLASTIC 1.093-1.125
11 0G3430 1 GASKET AIR IN TOP DUCT
12 0G3402 1 DUCT AIR IN ROOF
13 090388 13 SCREW HHTT M6-1.0X12 ZINC
14 0G3422 1 TOP DIVIDER PANEL
15 0G5237 1 FOAM, SIDE ENCLOSURE
16 0G3399 1 ENCLOSURE SIDE / BACK
17 0D3472 1 GROMMET OVAL 31.75X50.8
18 0G4933 18 SCREW SWT 1/4-20X5/8 W/W
23 0G5238 1 FOAM BACK ENCLOSURE ALT SIDE
24 0G3397 1 ENCLOSURE ROOF
25 0G4391 1 ENCLOSURE, BACK PANEL 530 RV
26 0G5239 1 FOAM BACK PANEL ENCLOSURE
28 0G3392 1 UPPER BLOWER HOUSING
29 0G3754 1 UPPER BLOWER HOUSING GASKET
30 0G3398 1 EXHAUST DIVIDER PANEL
31 0G3912 1 MUFFLER HOLD DOWN BRACKET
32 0G3400 1 ENCLOSURE EXHAUST SIDE PANEL
33 0G5240 1 FBR GLASS, ENCLOSURE MFLR BACK
34 0G5242 1 FOAM EXHAUST END ENCL FRONT
35 0G5241 2 FBR GLASS, ENCLOSURE MFLR SIDE
36 045756 9 SCREW HHTT M6-1.0X10 ZYC
37 0G5755 1 BUMPER
38 0G5761 1 STAND OFF
39 022473 1 WASHER, FLAT 1/4
40 022097 1 WASHER, LOCK 1/4
41 022287 1 SCREW HHC 1/4-20 X 3/4 G5
42 0G3429 1 GASKET, SCROLL DUCT

SHEET METAL PAINT/MATERIAL CODE LEGEND

The following exploded views contain part numbers of various sheet metal components. Only the base part number is listed. When ordering sheet metal, the
correct color and material information must be included as a suffix at the end of the part number as shown below.
Material Color Example: Desc. Part No. Material Color Order As"
S = Steel G = Gray Roof 0G3397 S = Steel G = Gray 0G33970ST08
B = Black Upper Blower Hsg. 0G3392 S = Steel B = Black 0G33920ST03

41
Exploded Views & Parts Lists Control Panel Drawing No. 0H3635-C

42
Control Panel Drawing No. 0H3635-C Exploded Views & Parts Lists

ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION

1 045757 1 SCREW HHC M6-1.0 X 25 G8.8 36 082025 4 NUT HEX LOCK M5-0.8 NYINS ZINC
2 0F5458 2 SCREW PLASTITE HI-LOW #10X3/8 37 0F9719 1 ASSY PCB VREG AIR COOLED 2006
3 023484S 1 BUSHING SNAP SB-1093-937 38 0G3977 1 ASSY PCB RV CONTROLLER
4 0G9081* 1 WIRE HARNESS C/PNL FRAME 39 0G3530 1 C/PNL FRAME RV
5 049813 1 NUT HEX M6 X 1.0 G8 YEL CHR 40 075476 2 SCREW PPHM M4-0.7 X 16
6 022473 2 WASHER FLAT 1/4-M6 ZINC 41 090987 2 SCREW PPHM M3-0.5 X 12
7 0A1658 1 WASHER LOCK SPECIAL 1/4" 42 0C2174 1 RELAY 12V 25A SPST
8 0G3380 1 FUEL PUMP MOUNTING BRACKET 43 031879 2 WASHER FLAT #4 ZINC
9 0F9176 28.75 HOSE,1/4" SAE30R7 44 0D9784 2 NUT HEX LOCK M3-0.5 NY INS
10 0G3662A 1 CLAMP HOSE BAND .50 45 075235 4 SCREW HHC M5-0.8 X 30 G8.8
11 028414 1 BARBED STR 1/8NPT X 1/4 46 074908 4 SCREW HHTT M5-0.8 X 10 BP
12 0D3700 5 NUT FLANGE M6-1.0 NYLOK 47 075210A 1 BLOCK 1 POSITION, 4 TAB
13 0G5225 1 FUEL PUMP 48 0E6480 2 NUT HEX LOCK M4-0.7 NY INS
14 028916 1 ELBOW 90D STREET 1/8 BRASS 49 090144 (5500W) 1 CIRCT BRK 20X1 MAG 10-32 CARL
15 087769 1 FILTER FUEL 1/8P-1/4H 090145 (6500W) 1 CIRCT BRK 30X1 MAG 10-32 CARL
16 025965 1 SCREW HHC 1/4-20 X 2-1/4 G5 50 090145 1 CIRCT BRK 30X1 MAG 10-32 CARL
17 022097 2 WASHER LOCK M6-1/4 (4500W, 5500W, 6500W)
18 0G5318 1 AC HARNESS 530RV (5500 + 6500W) 51 0C2417A 1 EARTH STRAP
0H3634 1 AC HARNESS 530RV EVAP (4500W) 52 0G5986 1 NYLON SPACER .26 X 1.00 X 1.73
19 0G4602 1 GROMMET, DOUBLE SLIT 53 061669 1 PLUG, PLASTIC .75 (5410-1/5412-
20 0C7968 3 NUT HEX JAM 3/8-16 BRASS 1/5414-1 ONLY)
21 022237 2 WASHER LOCK 3/8 54 059502 1 BARBED EL 90 NPT X 5/16
22 0A4456 1 WASHER LOCK SPECIAL 3/8 (5751/5752/5753 ONLY)
23 0C7423 1 STUD 3/8-16 X 2-1/4 BRASS 55 069598 1 BULKHEAD ADAPTER
24 022259 2 NUT HEX 5/16-18 STEEL (5751/5752/5753 ONLY)
25 022129 2 WASHER LOCK M8-5/16 56 035579 1 BUSHING REDUCER HEX TO 1/8 NPT
26 022145 1 WASHER FLAT 5/16-M8 ZINC (5751/5752/5753 ONLY)
27 0E0593 1 STUD, 1/4-20 TO 5/16-18 57 035483 1 NIPPLE PIPE 1/8 NPT X 1
28 0D8502 1 NEUTRAL CONNECTOR UL (5751/5752/5753 ONLY)
29 0G5233 2 SCREW PPHTF #8-18 X 1/2 AB 58 0G0247 1 SOLENOID 12 VDC (5751/5752/5753
30 0G3825 1 CONTROL PANEL COVER ONLY)
31 0G3689 1 C/PNL FACE 59 028740 1 BARBED EL 90 1/8 NPT X
32 092036 4 SCREW PPHM #6-32 X 1/4 SEMS (5751/5752/5753 ONLY)
33 0A9611 1 FUSE 7.5AXBK/AGC7.5NX
34 032300 1 HOLDER FUSE *HARNESS NOT SHOWN
35 0G4215 1 SWITCH RKRSPDT(ON)OFF(ON)ILLUM

43
Exploded Views & Parts Lists Base & Pulley Drawing No. 0G7720-B

44
Base & Pulley Drawing No. 0G7720-B Exploded Views & Parts Lists

ITEM PART NO. QTY. DESCRIPTION

1 0G3377 1 TRAY, 530 RV

2 081105 2 NUT FLANGE 5/16-18 LOCK
3 022259 8 NUT HEX 5/16-18 STEEL
4 022129 12 WASHER LOCK M8-5/16
5 022145 13 WASHER FLAT 5/16-M8 ZINC
6 0G5217 2 SCREW HHC 3/8-24 X 1-1/2 G8
7 0G3748 1 BELT V-RIBBED 4L X 43.75" LG
8 046526 2 WASHER LOCK M10
9 022131 2 WASHER FLAT 3/8-M10 ZINC
10 0G3384 1 ALTERNATOR PULLEY
11 0C7758A 4 VIB MNT 1.5X1.38X5/16-18 DR 45
12 0C1751 1 FAN 7" DIA (NYLON)
13 0C2824 11 SCREW HHTR #10-32 X 9/16
14 022473 7 WASHER FLAT 1/4-M6 ZINC
15 022097 7 WASHER LOCK M6-1/4
16 043116 7 SCREW HHC M6-1.0 X 12 G8.8
17 0G3383 1 ENGINE PULLEY
18 0G4350 1 FAN ENGINE PULLEY RV
19 0G3379 2 BRACKET MUFFLER SUPPORT
20 0C3062 2 BOLT CARR 5/16-18 X 1
21 0G4429 1 EDGE TRIM W/ 3/4" HOLLOW CYL.
22 0G3391 1 BLOWER HOUSING WALL
23 0G3742 1 GASKET, LOWER BLOWER HOUSING
24 0G7670 1 FRAME GT530 RV MOUNTING
25 0E0588 1 SPACER, SAFETY BOLT .375 I.D.
26 0G4702 2 SCREW HHC 5/16-18 X 3 SPC
27 029451 1.5ft TAPE ELEC UL FOAM 1/8 X 1/2
28 0G3426 1 DUCT AIR OUT
29 0G5676 1 GASKET,AIR OUT DUCT
0G5676A 1 GASKET, AIR OUT DUCT OPPOSITE SIDE
30 0G4692 1 SCREEN, BOTTOM AIR OUT
31 022473 3 WASHER FLAT 1/4-M6 ZINC
32 0A2110 3 SCREW SWAGE 1/4-20 X 1/2 ZYC
33 0G3410 5 ISOLATION SPRING
34 0G3393 1 MUFFLER, 530 RV
0G7887 1 MUFFLER. 530 RV (MODELS: 5410-1 / 5412-1 / 5414-1 ONLY)
35 025145 1 BOLT U 5/16-18 X 1.25 W/SADDLE
36 0C8565 4 SCREW SHC M8-1.25 X 18 G8.8
37 056892 1 SCREW CRIMPTITE 10-24 X 3/8
38 089680 1 SCREEN SPARK ARRESTOR
39 094670 2 CLAMP EXHAUST
40 0G3394 1 EXHAUST FLEX
41 0G3395 1 EXHAUST MANIFOLD
42 056893 6 SCREW CRIMPTITE 10-24 X 1/2
43 023897 6 WASHER FLAT #10 ZINC
44 0G4260 2 GASKET, EXH BASE, 530 RV
45 0E9369 2 GASKET, EXHAUST GT530

45
Exploded Views & Parts Lists Engine Accessories Drawing No. 0G7718-K

46
Engine Accessories Drawing No. 0G7718-K Exploded Views & Parts Lists

ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION

1 0G7670 1 FRAME 50 0G3386 1 OIL FILTER SUPPORT

3 0G3404 1 ENGINE WRAPPER, STARTER SIDE 51 0A2311 2 SCREW SWAGE 1/4-20 X 1
4 0E9507 8 SCREW HHFC M8-1.25 X 14 52 070185B 1 OIL FILTER
5 023484S 1 SNAP BUSHING 53 0D9235 1 OIL PRESSURE SWITCH 5 PSI
6 056893 14 SCREW CRIMPTITE 10-24 X 1/2 54 0G4793 1 SWITCH, THERMAL 270F
7 0G4129 1 SHIELD WRAPPER, CYLINDER #1 55 043182 2 WASHER, LOCK M3
8 0C8563 12 SCREW HHFC M6-1.0 X 12 G8.8 56 0C1085 2 SCREW PPHM M3-0.5 X 8
9 0G3405 1 ENGINE WRAPPER, BACK 58 0G4576 1 BRACKET, OIL CHECK TUBE
10 0G4985A 1 BACKPLATE 59 0A2110 1 SCREW SWAGE 1/4-20 X 1/2
11 0E9525A 1 ASSY, FLYWHEEL & RING GEAR 29D 60 0G3407 1 WRAPPER ENGINE VALLEY
12 0E4997 1 ASSY, GROUND WIRE CONNECTOR 61 0G3915 1 WRAPPER UPPER VALLEY
13 067198N 1 WASHER,BELV-20 X 2.2 62 0G3840 1 WRAPPER INNER CYLINDER #2
14 067890 1 NUT HEX M20-1.5 G8 63 0G3839 1 WRAPPER INNER CYLINDER #1
15 0G3911 1 BLOWER HOUSING 64 0E9368 2 SPARKPLUG
16 0G4130 1 SHIELD WRAPPER, CYLINDER #2 65 0G7671 1 OIL LINE OUT
17 082774 1 KEY, WOODRUFF 4 X 19D 66 0G3389 1 OIL LINE IN
18 0G3454 1 BREATHER HOSE 67 0A7094 2 SCREW PPHM #4-40 X 1/4
19 022131 3 WASHER FLAT 3/8 M10 ZINC 68 0D8590 1 ASSEMBLY, BI-METAL/HEATER
20 0G5221A 1 IGNITION COIL CYLINDER #1 69 0D8591 1 CHOKE SOLENOID
21 0G5221B 1 IGNITION COIL CYLINDER #2 70 0G3984 1 CONTROLLER ASSEMBLY
22 0G6432 4 SCREW HHFC M6-1.0 X 25 SEMS 71 043146 2 SCREW HHC M6-1.0 X 10 G8.8
23 0E9319 2 GASKET, INTAKE 72 022097 6 WASHER LOCK M6-1/4
24 0E9333 1 INTAKE MANIFOLD 73 0D6342 1 BALL STUD, 10 MM
25 040976 4 SCREW SHC M8-1.25 X 20 G12.9 74 0D9784 1 NUT HEX LOCK M3-0.5
26 0E9471 1 GASKET, MANIFOLD TO CARB/MIXER 75 0G4016 1 BRACKET, CONTROLLER SUPPORT
27 0E9383D 1 CARBURETOR 76 043116 2 SCREW HHC M6-1.0 X 12 G8.8
28 0G9640 1 ROD, CHOKE CONTROL 77 0F1177 1 ASSY, GROUNDING WIRE W/O DIODES
29 0G3890 1 ASSY GOVERNOR ROD 78 077091 1 COTTER PIN
30 0G4378 1 GASKET, AIRBOX/CARB 80 075763A 1 BOOT, BATT. CABLE
31 040173 1 CLAMP, HOSE WORM GEAR 81 0742600173 1 WIRE ASSY. BATT. POS.
32 0G3406 1 WRAPPER, ENGINE OIL ADAPTOR 83 022473 2 WASHER, FLAT 1/4-M6
33 0G3455 1 SNORKEL, AIR BOX 84 061906 2 SCREW HHC M8-1.25 X 85
34 0G3413 1 AIRBOX BASE 85 049813 2 NUT M6-1.0
35 078601 1 AIR FILTER 86 056892 2 SCREW CRIMPTITE 10-24 X 3/8
36 0G5057 1 AIRBOX SEAL 87 0E9323 1 START MOTOR
37 0E9511B 1 AIRBOX QUARTER KNOB 88 022129 2 WASHER, LOCK M8-5/16
38 0G3414 1 AIRBOX COVER 89 0A4456 1 WASHER, LOCK SPECIAL 3/8
40 0G3408 1 OIL DRAIN LINE 90 022746 4 SCREW HHC 3/8-16 X 1-3/4 G5
41 045756 4 SCREW HHTT M6-1.0 X 10 YELLOW 91 055934M 1 CLAMP VINYL .75 X .343
CHROME 92 0G6725 1 INSULATOR
42 0E0998 1 CLAMP, VINYL 9.5 O.D. 93 0G6729 1 GASKET, MANIFOLD TO CARB/MIXER
43 0G3432 2 3/4 NPT TO 3/8 O.D. FLARE 94 078643C 2 BOLT,CARB MOUNT M6-1.0 X 95
44 0E0393A 1 ASSY, CAP AND DIPSTICK 95 096290A 2 STUD M6-1.0 X 100
45 0E0361B 1 OIL DRAIN/DIPSTICK TUBE 96 046526 3 WASHER LOCK M10
46 043790 1 90 DEGREE ELBOW 3/8 NPT X 3/8 97 0G9148 1 PLUG, RUBBER (4703, 5, 6 & 7)
BARBED 98 0G7757A 1 HOSE MOLDED EVAP. PORT (05751,
47 0G3662B 2 HOSE OETIKER CLAMP 05752 & 05753)
48 0F0452B 8 HOSE, 3/8 I.D. 99 0H4269 1 SCREW, BHSC M6-1 X 8
49 0G4426 1 ASSY, OIL DRAIN FITTING 100 0G9062 1 SCREW BHSC M6-1 X 8MM BLACK

47
Exploded Views & Parts Lists 530 RV Engine Drawing No. 0G7719-B

48
530 RV Engine Drawing No. 0G7719-B Exploded Views & Parts Lists

ITEM PART NO. QTY. DESCRIPTION

1 0E3812 2 SEAL D 35 X 48.2

2 0D4788 1 3/8 SQUARE HEAD PLUG
3 073144 9 SCREW HHFC M8 1.25 X 45
4 0G7260A 1 GEAR COVER
5 078699B 6 SLEEVE DOWEL PIN
6 0A5776 1 11/32 DIAMETER PRESSURE RELIEF BALL
7 0E9482 1 OIL PRESSURE SPRING
8 0C5315A 1 GEAROTOR, OUTER
9 0C5314A 1 GEAROTOR, INNER
10 0E9379 1 SCREEN, OIL PICK-UP
11 0E9382 1 COVER, GEROTOR
12 0G0919 3 SCREW, HHFCS M6-1.0 x 12
13 0E3372A 1 BREATHER SEPARATOR
14 0E9345 1 GEAR, GEAROTOR
15 076390 4 RETAINER RING
16 0G4379 2 PISTON RING SET
17 0G4331 2 PISTON
18 076389 2 PISTON PIN
19 0G1054 2 CONNECTING ROD ASSEMBLY
20 0G1063G 1 CRANKSHAFT
21 093064 1 OIL FILL CAP
22 0E9334F 1 COVER ROCKER W/FILL
23 080318 8 SCREW HHFC M6-1.0 X 25
24 0E9352 2 GASKET, VALVE COVER
25 0E9368 2 SPARK PLUG
26 077168 12 SCREW HHC M8-1.25 X 56
27 084186 4 WASHER, VALVE SPRING
28 088156 2 SEAL, VALVE STEM
29 0C4390 4 VALVE SPRING
30 0C3733 4 VALVE RETAINER
31 0C3592 8 KEEPER, VALVE SPRING
32 077161 4 STUD, ROCKER ARM
33 077160 4 ROCKER ARM
34 076307 4 JAM NUT, ROCKER ARM
35 0E9353A 2 PUSH ROD GUIDE PLATE
36 0E9304 1 CYLINDER HEAD CYL. 1
37 0C3591 2 INTAKE VALVE
38 0C3590 2 EXHAUST VALVE
39 0E9351 2 GASKET CYLINDER HEAD
40 0G5728 1 SCREEN
41 0E9455E 4 PUSHROD
42 083235 4 TAPPET
43 0G7679 1 CAM SHAFT & GEAR
44 0E9350 1 GASKET, CRANKCASE
45 0E9334G 1 COVER ROCKER
46 0E9305 1 CYLINDER HEAD CYL 2
47 0E9429C 1 CRANKCASE
48 0E9366 1 GASKET, BREATHER ASSEMBLY
49 0G5670 1 BREATHER ASSY
50 0C8566 1 SCREW HHFC M6-1.0 X 20
51 0C5943 1 SEAL, OIL PASSAGE
52 0G0273 1 GASKET KIT
53 0G5896 1 BREATHER KIT
54 0G0275 1 KIT HEAD ASSY CYLINDER #1
55 0G0276 1 KIT HEAD ASSY CYLINDER #2

49
Exploded Views & Parts Lists Rotor & Stator Drawing No. 0G3953-B

50
Rotor & Stator Drawing No. 0G3953-B Exploded Views & Parts Lists

ITEM PART NO. QTY. DESCRIPTION

1 052858 6 NUT TOP LOCK FL M8-1.25

2 075237 4 WASHER, SPRNG CENTER
3 075242 4 SPRING, GEN. MOUNT
4 0C1878 2 SUPPORT, SLIDE
5 073146 4 SLIDE, NYLON
6 052203 2 SCREW HHC M8-1.25 X 70 G8.8
7 022145 6 WASHER FLAT 5/16-M8 ZINC
9 0G3913 4 STUD, 530 RV STATOR
10 029459 2 TENSION SPRING
11 075215 2 WASHER, SPRING CENTR
12 0G3382 1 LOWER BEARING CARRIER
13 0G3877H 1 RTR 200 4.5AD1 RV
0G3878H 1 RTR 200 5.5AD1 RV
0G3879H 1 RTR 200 6.5AD1 RV
14 0G3893H 1 STR 200-4.5AD1 RV
0G3894H 1 STR 200-5.5AD1 RV
0G3895H 1 STR 200-6.5AD1 RV
15 0G3381 1 UPPER BEARING CARRIER
16 022129 4 WASHER LOCK M8-5/16
17 045771 4 NUT HEX M8-1.25 G8 CLEAR ZINC
18 066386 1 ASSEMBLY, BRUSH HOLDER
19 066849 2 SCREW HHTT M5-0.8 X 16
20 0G3542 1 FAN UPPER ALTERNATOR
21 022131 1 WASHER FLAT 3/8-M10 ZINC
22 042633 1 SCREW HHC 3/8-24 X 1 G5
23 022237 1 WASHER LOCK 3/8

51
Warranty

CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with Generac Power
Systems, Inc. (Generac), are pleased to explain the Emission Control System warranty on your new 2008 and later generator. New equip-
ment that use small spark-ignited engines must be designed, built, and equipped to meet stringent anti-smog standards for the state of
California and the federal government. Generac will warrant the emission control system on your generator for the period of time listed below
provided there has been no abuse, neglect, unapproved modification or improper maintenance of your equipment.
Your emission control system may include parts such as the: carburetor, ignition system, fuel system catalytic converter, and other associ-
ated emission-related components (if equipped).

MANUFACTURERS WARRANTY COVERAGE:

This emission control system is warranted for two years. If, during such warranty period, any emission-related part on your equipment is
found to be defective in materials or workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service
Dealer.

OWNER'S WARRANTY RESPONSIBILITIES:

As the generator owner, you are responsible for the completion of all required maintenance as listed in your factory supplied Owner's
Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your generator, but Generac
cannot deny warranty solely due to the lack of receipts.
As the generator owner, you should be aware that Generac may deny any and/or all warranty coverage or responsibility if your generator,
or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unapproved modifications, or the use of counterfeit
and/or "grey market" parts not made, supplied or approved by Generac.
You are responsible for contacting a Generac Authorized Warranty Dealer as soon as a problem occurs. The warranty repairs should be
completed in a reasonable amount of time, not to exceed 30 days.
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Dealer. To locate the
Generac Authorized Warranty Service Dealer nearest you, call our toll free number:

1-800-333-1322
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty (ECS
Warranty), which is provided to you by Generac pursuant to California and federal law. See also the "Generac Limited Warranties for Generac
Power Systems, Inc.," which is enclosed herewith on a separate sheet, also provided to you by Generac. Note that this warranty shall not
apply to any incidental, consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replace-
ment of the defective part(s). This warranty is in place of all other warranties, expressed or implied. Specifically, Generac makes no other
warranties as to the merchantability or fitness for a particular purpose. Some states do not allow limitations on how long an implied warranty
lasts, so the above limitation may not apply to you.
The ECS Warranty applies only to the emission control system of your new equipment. If there is any conflict in terms between the ECS
Warranty and the Generac Warranty, the Generac Warranty shall apply. Both the ECS Warranty and the Generac Warranty describe important
rights and obligations with respect to your new engine.
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service, evidence
must be presented showing the date of the sale to the original purchaser/owner.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the following address:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297 WHITEWATER, WI 53190
Part 1

Part No. 0H1912 Rev. A 05/09

52
 Warranty

EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS warranty) for equipment using small spark-ignited engines:

(a) Applicability: This warranty shall apply to equipment that uses small off-road engines. The ECS Warranty period shall begin on the date the new equip-
ment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.

(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or equipment and to each sub-
sequent purchaser/owner that the ECS when installed was:

(1) Designed, built and equipped so as to conform with all applicable regulations; and

(2) Free from defects in materials and workmanship which cause the failure of a warranted part at any time during the ECS Warranty Period.

(c) The warranty on emissions-related parts will be interpreted as follows:

(1) Any warranted part that is not scheduled for replacement as required maintenance in the Owner's Manual shall be warranted for the ECS Warranty
Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac according to Subsection (4) below. Any
such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.

(2) Any warranted part that is scheduled only for regular inspection as specified in the Owner's Manual shall be warranted for the ECS Warranty
Period. A statement in the Owners Manual to the effect of "repair or replace as necessary" shall not reduce the ECS Warranty Period. Any such
part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.

(3) Any warranted part that is scheduled for replacement as required maintenance in the Owner's Manual shall be warranted for the period of time prior
to first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by
Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS warranty shall be warranted for
the remainder of the period prior to the first scheduled replacement point for that part.

(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a
Generac Authorized Warranty Service Facility.

(5) Notwithstanding the provisions of subsection (4) above, warranty services or repairs must be provided at Generac Authorized Service Facilities.

(6) When the engine is inspected by a Generac Authorized Warranty Service Facility, the purchaser/owner shall not be held responsible for diagnostic
costs if the repair is deemed warrantable.

(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand
for such parts.

(8) Any Generac authorized and approved emission-related replacement parts may be used in the performance of any ECS warranty maintenance or
repairs and will be provided without charge to the purchaser/owner. Such use shall not reduce Generac ECS Warranty obligations.

(9) Unapproved, add-on, modified, counterfeit and/or "grey market" parts may not be used to modify or repair a Generac engine. Such use voids this
ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any
warranted parts of Generac equipment caused by the use of such an unapproved, add-on, modified, counterfeit and/or "grey market" part.

EMISSION RELATED PARTS MAY INCLUDE THE FOLLOWING (IF EQUIPPED):

1) FUEL METERING SYSTEM 4) AIR INJECTION SYSTEM

A. CARBURETOR AND INTERNAL PARTS A. PULSE AIR VALVE
B. PRESSURE REGULATOR 5) EXHAUST SYSTEM
2) AIR INDUCTION SYSTEM A. CATALYST
A. INTAKE MANIFOLD B. THERMAL REACTOR
B. AIR FILTER C. EXHAUST MANIFOLD
3) IGNITION SYSTEM
A. SPARK PLUGS
B. IGNITION COILS / MODULE

Part 2

Part No. 0H1912 Rev. A 05/09

53
 Warranty

GENERAC POWER SYSTEMS THREE-YEAR LIMITED WARRANTY

FOR GENERAC RECREATIONAL VEHICLE GENERATORS
NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a period of 3
(three) years of operation from the date of original sale, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part
which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Facility, is found to be defective
under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to
be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Facility. All transportation costs under
the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac
generators sold and rated for Recreational Vehicle (RV) applications, as Generac has defined Recreational Vehicle generator applications.
The factory recommends exercising the unit one half-hour every month.
WARRANTY SCHEDULE COMMERCIAL APPLICATIONS
YEAR ONE 100% (one hundred percent) coverage on part(s), labor, removal and reinstallation listed:
Engine All components
Alternator All components
WARRANTY SCHEDULE CONSUMER/PERSONAL APPLICATIONS
YEARS ONE AND TWO 100% (one hundred percent) coverage on part(s), labor, removal and reinstallation listed:
Engine All components
Alternator All components
YEAR THREE 100% (one hundred percent) only on selected part(s) and labor listed [Any labor and part(s) not listed, and removal and
reinstallation are the owners responsibility]:
Rotor, Stator, Computer Control Board (part numbers 0A6060 and 0A3369) and inverter, (if applicable with regard to the generator) Cylinder
Block, Cylinder Head, Crankshaft, Piston(s), Valve, Valve Lifter(s), Intake and Exhaust Manifolds
Generac RV generators manufactured prior to December 31, 1997, DO NOT have a transferable warranty. Generac RV generators manu-
factured after January 1, 1998, have a transferable warranty to the second owner ONLY for the remainder of the three-year limited warranty.
Proof-of-purchase is required and must be presented to a Generac Authorized Warranty Service Facility prior to the performance of any
warranty service.
All warranty expense allowances are subject to the conditions defined in Guardians Warranty Policies and Procedures Guide.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
Generac Guardian generators that utilize non-Generac replacement parts.
Costs of normal maintenance, adjustments, installation and start-up.
Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by Generac
Power Systems.
Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.
Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all mechani-
cal devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty will not cover repair when
normal use has exhausted the life of a part(s) or engine.
Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing,
lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
Damage related to rodent and/or insect infestation.
Products that are modified or altered in a manner not authorized by Generac in writing.
Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement
of the defective part(s).
Failure due to misapplication.
Telephone, cellular phone, facsimile, internet access or other communication expenses.
Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty
period.
Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.
Rental equipment used while warranty repairs are being performed.
Overnight freight costs for replacement part(s).
Overtime labor.
Starting batteries, fuses, light bulbs and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES
AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty
lasts, so the above limitation may not apply to you.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE
LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.
This warranty gives you specific legal rights. You also have other rights from state to state.
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297 WHITEWATER, WI 53190
Rev. A 06.09
Part No. 0H3467 Revision B (04/15/10) Printed in U.S.A.